Method for manufacturing display device

ABSTRACT

One object is to provide a method for manufacturing a display device in which shift of the threshold voltage of a thin film transistor including an oxide semiconductor layer can be suppressed even when ultraviolet light irradiation is performed in the process for manufacturing the display device. In the method for manufacturing a display device, ultraviolet light irradiation is performed at least once, a thin film transistor including an oxide semiconductor layer is used for a switching element, and heat treatment for repairing damage to the oxide semiconductor layer caused by the ultraviolet light irradiation is performed after all the steps of ultraviolet light irradiation are completed.

TECHNICAL FIELD

The present invention relates to a method for manufacturing a displaydevice including an oxide semiconductor.

BACKGROUND ART

In recent years, a technique for forming a thin film transistor (TFT) byusing a semiconductor thin film (having a thickness of approximatelyseveral nanometers to several hundred nanometers) formed over asubstrate having an insulating surface has attracted attention. Thinfilm transistors are applied to a wide range of electronic devices suchas ICs or electro-optical devices, and prompt development of thin filmtransistors that are to be used as switching elements in image displaydevices, in particular, is being pushed. As a transparent electrodematerial needed in an image display device such as a liquid crystaldisplay, a metal oxide typified by indium oxide is used.

In addition to a transparent electrode material, there are various kindsof metal oxides, which are used for a wide range of applications. Somemetal oxides have semiconductor characteristics. Examples of metaloxides (oxide semiconductors) having semiconductor characteristicsinclude tungsten oxide, tin oxide, indium oxide, and zinc oxide. PatentDocuments 1 and 2 disclose a thin film transistor in which such an oxidesemiconductor is used as a channel formation region and a display devicein which the thin film transistor is used for a switching element of apixel or the like.

Patent Document 3 discloses that the threshold voltage of a thin filmtransistor including an oxide semiconductor is shifted in the negativedirection by ultraviolet light irradiation.

REFERENCE

-   [Patent Document 1] Japanese Published Patent Application No.    2007-123861-   [Patent Document 2] Japanese Published Patent Application No.    2007-096055-   [Patent Document 3] Japanese Published Patent Application No.    2009-182194

DISCLOSURE OF INVENTION

In an active matrix display device, electric characteristics of thinfilm transistors included in a circuit are important and performance ofthe display device depends on the electric characteristics of thin filmtransistors. Among the electric characteristics of thin filmtransistors, a threshold voltage (Vth) is particularly important. Whenthe threshold voltage is high or is negative even when the field effectmobility is high, it is difficult to control the circuit. In the casewhere a thin film transistor has a high threshold voltage, the thin filmtransistor cannot perform a switching function as the TFT and might be aload when the TFT is driven at low voltage. In the case where thethreshold voltage is negative, current tends to flow between a sourceelectrode and a drain electrode even when the gate voltage is 0 V, thatis, the thin film transistor tends to be in a so-called normally-onstate.

When a thin film transistor including an oxide semiconductor layer isirradiated with ultraviolet light, the threshold voltage is shifted inthe negative direction. In a process for manufacturing a display devicein which an oxide semiconductor layer is used for a switching element,ultraviolet light irradiation is performed in many steps typified by astep of attachment of substrates using an ultraviolet curable resin.That is, there is a problem in that when a display device in which athin film transistor including an oxide semiconductor layer is used fora switching element is manufactured, the threshold voltage of the thinfilm transistor shifts in the negative direction in the manufacturingprocess.

In view of the problem, one object is to provide a method formanufacturing a display device in which shift of the threshold voltageof a thin film transistor including an oxide semiconductor layer can besuppressed even when ultraviolet light irradiation is performed in theprocess for manufacturing the display device.

One embodiment of the present invention is a method for manufacturing adisplay device in which ultraviolet light irradiation is performed atleast once, a thin film transistor including an oxide semiconductorlayer is used for a switching element, and heat treatment for repairingdamage to the oxide semiconductor layer caused by the ultraviolet lightirradiation is performed after all the steps of ultraviolet lightirradiation are completed.

One embodiment of the present invention is a method for manufacturing adisplay device including the steps of: forming a thin film transistorincluding an oxide semiconductor layer and being electrically connectedto a pixel electrode in a pixel portion over a first substrate; forminga sealant including an ultraviolet curable resin over any one of thefirst substrate and a second substrate so as to surround a regionincluding at least the pixel portion; dropping liquid crystal to form aliquid crystal layer in the region surrounded by the sealant formed overany one of the first substrate and the second substrate; attaching thefirst substrate and the second substrate so that the region includingthe pixel portion and the liquid crystal layer overlap with each other;curing the sealant with ultraviolet light irradiation; and performingheat treatment for repairing a damage to the oxide semiconductor layercaused by irradiation with the ultraviolet light.

One embodiment of the present invention is a method for manufacturing adisplay device including the steps of: forming a thin film transistorincluding an oxide semiconductor layer and being electrically connectedto a pixel electrode in a pixel portion over a first substrate; forminga sealant including an ultraviolet curable resin over any one of thefirst substrate and a second substrate so as to have an opening andsurround a region including the pixel portion; attaching the firstsubstrate and the second substrate so that the region including thepixel portion and the region surrounded by the sealant overlap with eachother; curing the sealant with ultraviolet light irradiation; injectingliquid crystal to form a liquid crystal layer in a region surrounded bythe first substrate, the second substrate, and the sealant; andperforming heat treatment for repairing a damage to the oxidesemiconductor layer caused by irradiation with the ultraviolet light.

One embodiment of the present invention is a method for manufacturing adisplay device including the steps of: forming a thin film transistorincluding an oxide semiconductor layer and being electrically connectedto a pixel electrode in a pixel portion over a first substrate; forminga sealant including an ultraviolet curable resin over any one of thefirst substrate and a second substrate so as to surround a regionincluding at least the pixel portion; dropping a liquid crystalincluding an ultraviolet curable resin to form a liquid crystal layer inthe region surrounded by the sealant formed over any one of the firstsubstrate and the second substrate; attaching the first substrate andthe second substrate so that the region including the pixel portion andthe liquid crystal layer overlap with each other; curing the sealant andthe liquid crystal including the ultraviolet curable resin withultraviolet light irradiation; and performing heat treatment forrepairing a damage to the oxide semiconductor layer caused byirradiation with the ultraviolet light.

The liquid crystal may exhibit a blue phase. The pixel electrode ispreferably subjected to surface treatment by ultraviolet lightirradiation. The sealant may be irradiated with ultraviolet light to betemporarily cured immediately after formation of the sealant. A pair ofsubstrates which are attached to each other may be divided after curingof the sealant. The sealant may be formed in the driver circuit portionin which another thin film transistor including an oxide semiconductorlayer is formed.

One embodiment of the present invention is a method for manufacturing adisplay device including the steps of: forming a thin film transistorincluding an oxide semiconductor layer in a pixel portion over a firstsubstrate; forming a light-emitting element electrically connected tothe thin film transistor over the thin film transistor; forming asealant including an ultraviolet curable resin over any one of the firstsubstrate and a second substrate so as to surround a region including atleast the pixel portion; attaching the first substrate and the secondsubstrate; curing the sealant with ultraviolet light irradiation; andperforming heat treatment for repairing a damage to the oxidesemiconductor layer caused by irradiation with the ultraviolet light.

The region surrounded by the first substrate, the second substrate, andthe sealant may be filled with a filler including an ultraviolet curableresin, and the sealant and the filler may be irradiated with ultravioletlight to be cured.

The heat treatment is preferably performed for greater than or equal to1 hour and less than or equal to 15 hours. Further, the heat treatmentis preferably performed at greater than or equal to 125° C. and lessthan or equal to 250° C.

Note that the display devices include display elements in thisspecification. As the display element, a liquid crystal element (alsoreferred to as a liquid crystal display element) or a light-emittingelement (also referred to as a light-emitting display element) can beused. The light-emitting element includes, in its category, an elementwhose luminance is controlled by a current or a voltage, andspecifically includes an inorganic electroluminescent (EL) element, anorganic EL element, and the like. Further, a display medium whosecontrast is changed by an electric effect, such as electronic ink, canbe applied to the display device.

In addition, the display device includes a panel in which the displayelement is sealed, and a module in which an IC or the like including acontroller is mounted on the panel. Furthermore, an element substrate,which corresponds to one embodiment before the display element iscompleted in a manufacturing process of the display device, is providedwith a means for supplying current to the display element in each of aplurality of pixels. Specifically, the element substrate may be in astate in which only a pixel electrode of the display element is formed,a state after formation of a conductive film to be a pixel electrode andbefore etching of the conductive film to form the pixel electrode, orany other states.

Note that the display device in this specification means an imagedisplay device, a display device, or a light source (including alighting device). Further, the display device includes all the followingmodules in its category: a module including a connector such as aflexible printed circuit (FPC), tape automated bonding (TAB) tape, or atape carrier package (TCP); a module having TAB tape or a TCP which isprovided with a printed wiring board at the end thereof; and a modulehaving an integrated circuit (IC) which is directly mounted on a displayelement by a chip on glass (COG) method.

In this specification, the wavelength of ultraviolet light used forultraviolet light irradiation is greater than or equal to 200 nm andless than or equal to 500 nm (preferably greater than or equal to 250 nmand less than 450 nm). In general, the wavelength of ultraviolet lightis less than or equal to 400 nm; however, the wavelength of ultravioletlight used for ultraviolet light irradiation also includes anelectromagnetic wave of greater than or equal to 400 nm.

When a display device is manufactured according to the method describedin one embodiment of the present invention, damage to an oxidesemiconductor layer caused by ultraviolet light irradiation can berepaired. According to this, even when the oxide semiconductor layer ofthe thin film transistor included in the display device is damaged byultraviolet light in the process for manufacturing the display device,shift of the threshold voltage of the thin film transistor in thenegative direction due to the damage by ultraviolet light irradiationcan be suppressed.

Moreover, the thin film transistor that functions as a switching elementin the display device can be normally off, so that the display devicehaving low power consumption and high reliability can be manufactured.

BRIEF DESCRIPTION OF DRAWINGS

In the accompanying drawings:

FIG. 1 is a flow chart of a method for manufacturing a display deviceaccording to one embodiment of the present invention;

FIG. 2 is a cross-sectional view of a display device according to oneembodiment of the present invention;

FIG. 3 is a flow chart of a method for manufacturing a display deviceaccording to one embodiment of the present invention;

FIG. 4 is a flow chart of a method for manufacturing a display deviceaccording to one embodiment of the present invention;

FIG. 5 is a cross-sectional view of a display device according to oneembodiment of the present invention;

FIG. 6 is a flow chart of a method for manufacturing a display deviceaccording to one embodiment of the present invention;

FIG. 7 is a cross-sectional view of a display device according to oneembodiment of the present invention;

FIGS. 8A to 8C are each a view of an electronic appliance to which adisplay device according to one embodiment of the present invention isapplied;

FIGS. 9A to 9F are each a view of an electronic appliance to which adisplay device according to one embodiment of the present invention isapplied;

FIG. 10 is a graph showing a spectrum of ultraviolet light used in anexample of the present invention; and

FIG. 11 is a graph showing the threshold voltage of each of thin filmtransistors in the example of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described indetail with reference to the accompanying drawings. However, the presentinvention is not limited to the description below, and it is easilyunderstood by those skilled in the art that modes and details disclosedherein can be modified in various ways. Therefore, the present inventionis not construed as being limited to description of the embodiments.

Note that for easy understanding, the position, size, range and the likeof each component illustrated in the drawings are not actual ones insome cases. Therefore, the present invention is not limited to theposition, size, range and the like disclosed in the drawings.

Note that in this specification, ordinal numbers such as “first”,“second”, and “third” are used in order to avoid confusion amongcomponents, and the terms do not limit the components numerically.

Embodiment 1

In this embodiment, a method for manufacturing a liquid crystal displaydevice illustrated in FIG. 2, in which a thin film transistor includingan oxide semiconductor layer is used, will be described with referenceto a flow chart of FIG. 1. The flow chart of FIG. 1 shows steps formanufacturing the liquid crystal display device illustrated in FIG. 2 bya one drop filling method (an ODF method).

First, a structure of the liquid crystal display device illustrated inFIG. 2 will be described. In the liquid crystal display device, a liquidcrystal layer 208 is sandwiched between a first substrate 201 that is anactive matrix substrate and a second substrate 206 that is a countersubstrate. A sealant 205 is formed between the first substrate 201 andthe second substrate 206 so as to surround a pixel portion 202 and adriver circuit portion 204, and retains the distance (a cell gap)between the first substrate 201 and the second substrate 206 with aspacer 235.

The liquid crystal display device illustrated in FIG. 2 has thefollowing structure on the active matrix substrate side. Over the firstsubstrate 201, a thin film transistor 210 including an oxidesemiconductor layer is formed in the pixel portion 202 and a thin filmtransistor 211 including an oxide semiconductor layer is formed in thedriver circuit portion 204. An insulating layer 220 and an insulatinglayer 221 are formed over the thin film transistor 210 in the pixelportion 202, a pixel electrode layer 230 electrically connected to oneof a source electrode layer and a drain electrode layer of the thin filmtransistor is formed over the insulating layer 221, and an alignmentfilm 232 is formed over the pixel electrode layer 230 and the insulatinglayer 221. Further, a conductive layer 240 is formed over the thin filmtransistor 211 in the driver circuit portion 204.

On the counter substrate side of the liquid crystal display deviceillustrated in FIG. 2, when the counter substrate is used as areference, a counter electrode layer 231 is formed over the secondsubstrate 206, and an alignment film 233 is formed over the counterelectrode layer 231. Further, a spacer 235 is provided over the counterelectrode layer 231.

A portion in which the pixel electrode layer 230 over the firstsubstrate 201, the counter electrode layer 231 over the second substrate206, and the liquid crystal layer 208 overlap with each othercorresponds to a liquid crystal element 213.

Note that in this embodiment, the driver circuit portion 204 is formedinside the frame of the sealant 205; however, the driver circuit portion204 is not necessarily formed in such a manner, and the entire or partof the driver circuit portion 204 may be formed outside the frame of thesealant 205. In the case of forming the driver circuit portion outsidethe frame of the sealant 205, the driver circuit portion may be formedover another substrate, and then mounted by a COG method, a wire bondingmethod, a TAB method or the like. For example, a scan line drivercircuit portion may be formed with a pixel portion inside the frame ofthe sealant over one substrate and a signal line driver circuit portionmay be formed over another substrate, and then mounted over the activematrix substrate.

Examples of a method for displaying a liquid crystal display devicedescribed in this embodiment are a twisted nematic (TN) mode, a supertwisted nematic (STN) mode, an in-plane-switching (IPS) mode, a fringefield switching (FFS) mode, a multi-domain vertical alignment (MVA)mode, a patterned vertical alignment (PVA) mode, an advanced super view(ASV) mode, an axially symmetric aligned microcell (ASM) mode, anoptical compensated birefringence (OCB) mode, an electrically controlledbirefringence (ECB) mode, a ferroelectric liquid crystal (FLC) mode, ananti-ferroelectric liquid crystal (AFLC) mode, a polymer dispersedliquid crystal (PDLC) mode, a polymer network liquid crystal (PNLC)mode, a guest-host mode, and a blue phase mode.

Next, in accordance with the flow chart of FIG. 1, a method formanufacturing the liquid crystal display device illustrated in FIG. 2 bya one drop filling method (an ODF method) will be described.

In this embodiment, in accordance with the flow chart of FIG. 1,formation of a thin film transistor including an oxide semiconductorlayer (a step 101), formation of a sealant (a step 102), formation of aliquid crystal layer (a step 103), attachment of a first substrate and asecond substrate (a step 104), curing of the sealant by ultravioletlight irradiation (a step 105), and heat treatment for repairing damageto the oxide semiconductor layer caused by the ultraviolet lightirradiation (a step 106) will be described in this order.

First, formation of the thin film transistor including an oxidesemiconductor layer (the step 101) will be described.

Over the first substrate 201, the thin film transistor 210 is formed inthe pixel portion 202 and the thin film transistor 211 is formed in thedriver circuit portion 204. Next, in the pixel portion 202, theinsulating layer 220 and the insulating layer 221 are formed over thethin film transistor 210. An opening is formed in the insulating layer220 and the insulating layer 221 so as to reach one of the sourceelectrode and the drain electrode of the thin film transistor 210, andthe pixel electrode layer 230 electrically connected to one of thesource electrode and the drain electrode of the thin film transistor 210through the opening can be formed over the insulating layer 221. Then,the alignment film 232 is formed over the insulating layer 221 and thepixel electrode layer 230. At this time, the insulating layer 221 is notnecessarily formed in the driver circuit portion 204; thus, theconductive layer 240 can be formed over the thin film transistor 211simultaneously in the formation of the pixel electrode layer 230.

Note that as the first substrate 201, a light-transmitting substrate canbe employed, and glass, ceramic, or plastic can be used. As plastic, afiberglass-reinforced plastics (FRP) plate, a polyvinyl fluoride (PVF)film, a polyester film, or an acrylic resin film can be used.

The thin film transistor 210 is a bottom gate thin film transistorformed in the following manner: a gate electrode layer is formed overthe first substrate 201, a gate insulating layer is formed over the gateelectrode layer, an oxide semiconductor layer is formed over the gateinsulating layer, and a source electrode layer and a drain electrodelayer are formed over the oxide semiconductor layer.

The gate electrode layer of the thin film transistor 210 is formed of asingle layer or a stacked layer including a conductive material such asmolybdenum, titanium, chromium, tantalum, tungsten, aluminum, copper,neodymium, and scandium, an alloy of any of these elements, or acompound (e.g., nitride) of any of these elements, by a film formationmethod such as a PVD method or a CVD method. As illustrated in FIG. 2, agate electrode layer is formed to protect an oxide semiconductor layerfrom light and thus the oxide semiconductor layer can be prevented frombeing directly irradiated with ultraviolet light or the like after aliquid crystal display device is completed.

The gate insulating layer of the thin film transistor 210 is formed of asingle layer or a stacked layer including any of silicon oxide, siliconnitride, silicon oxynitride, aluminum oxide, hafnium oxide, tantalumoxide, and the like, by a CVD method, a sputtering method, or the like.There is no particular limitation on the thickness of the gateinsulating layer; the thickness can be greater than or equal to 10 nmand less than or equal to 500 nm, for example. Note that the gateinsulating layer of the thin film transistor 210 is also included in thetransistor 211 and formed to cover the first substrate 201.

The oxide semiconductor layer of the thin film transistor 210 ispreferably formed by a sputtering method. As the oxide semiconductorlayer, an oxide of four metal elements such as an In—Sn—Ga—Zn—O-basedoxide semiconductor; an oxide of three metal elements such as anIn—Ga—Zn—O-based oxide semiconductor, an In—Sn—Zn—O-based oxidesemiconductor, an In—Al—Zn—O-based oxide semiconductor, aSn—Ga—Zn—O-based oxide semiconductor, an Al—Ga—Zn—O-based oxidesemiconductor, or a Sn—Al—Zn—O-based oxide semiconductor; an oxide oftwo metal elements such as an In—Zn—O-based oxide semiconductor, aSn—Zn—O-based oxide semiconductor, an Al—Zn—O-based oxide semiconductor,a Zn—Mg—O-based oxide semiconductor, a Sn—Mg—O-based oxidesemiconductor, or an In—Mg—O-based oxide semiconductor; or asingle-component metal oxide such as an In—O-based oxide semiconductor,a Sn—O-based oxide semiconductor, or a Zn—O-based oxide semiconductorcan be used. Note that silicon may be added to the metal oxide. Forexample, the oxide semiconductor layer may be formed using a targetcontaining SiO₂ at greater than or equal to 2 wt % and less than orequal to 10 wt %.

In particular, when an In—Ga—Zn—O-based metal oxide is used, a thin filmtransistor in which the resistance is sufficiently high when there is noelectric field and thus the off-current is sufficiently low and thefield effect mobility is high can be realized. Therefore, anIn—Ga—Zn—O-based metal oxide is suitable for an oxide semiconductorlayer used in a thin film transistor.

As a typical example of the In—Ga—Zn—O-based metal oxide, onerepresented by InGaO₃ (ZnO)_(m) (m>0) is given. Alternatively, there isa metal oxide represented by InMO₃ (ZnO)_(m) (m>0) in which M is usedinstead of Ga. Here, M denotes one or more of metal elements selectedfrom gallium (Ga), aluminum (Al), iron (Fe), nickel (Ni), manganese(Mn), and cobalt (Co) and the like. For example, M can be Ga, Ga and Al,Ga and Fe, Ga and Ni, Ga and Mn, Ga and Co, or the like. Note that theabove compositions are derived from the crystal structures and just anexample.

The thickness of the oxide semiconductor layer is greater than or equalto 1 nm and less than or equal to 200 nm, preferably greater than orequal to 5 nm and less than or equal to 30 nm. Note that an appropriatethickness differs depending on an oxide semiconductor material, and thethickness is set as appropriate depending on the material to be used.

Note that heat treatment is preferably performed on the oxidesemiconductor layer. By this heat treatment, the oxide semiconductorlayer can be dehydrated or dehydrogenated. The temperature of the heattreatment is set in the range of 300° C. to 750° C., preferably 400° C.to 700° C. For example, the substrate is introduced into an electricfurnace in which a resistance heating element or the like is used andthe oxide semiconductor layer is subjected to heat treatment at 450° C.under a nitrogen atmosphere for one hour. During the treatment, theoxide semiconductor layer is not exposed to the atmosphere so that entryof hydrogen (including water) is prevented. Note that the heat treatmentcan also be called as dehydrogenation (dehydration) treatment because itis effective in dehydrogenating (dehydrating) the oxide semiconductorlayer.

A heat treatment apparatus is not limited to an electric furnace and canbe an apparatus for heating an object by thermal radiation or thermalconduction from a medium such as a heated gas. For example, a rapidthermal anneal (RTA) apparatus such as a gas rapid thermal anneal (GRTA)apparatus or a lamp rapid thermal anneal (LRTA) apparatus can be used.

The source electrode layer or the drain electrode layer of the thin filmtransistor 210 can be formed by a PVD method such as a sputteringmethod, or a CVD method such as a plasma CVD method. As a material forthe source electrode layer or the drain electrode layer, an elementselected from aluminum, chromium, copper, tantalum, titanium,molybdenum, and tungsten; an alloy containing any of these elements as acomponent; or the like can be used. Alternatively, one or more materialsselected from manganese, magnesium, zirconium, beryllium, and thoriummay be used. Aluminum combined with one or more of elements selectedfrom titanium, tantalum, tungsten, molybdenum, chromium, neodymium, andscandium may be used. The source electrode layer or the drain electrodelayer can have a single-layer structure or a stacked structure includingtwo or more layers.

The thin film transistor 211 formed in the driver circuit portion 204can be also formed to have the same or substantially the same structureusing the same or substantially the same material as those of the thinfilm transistor 210. However, as described above, in the thin filmtransistor 211, the conductive layer 240 is preferably formed in aposition overlapping with a channel formation region of the oxidesemiconductor layer with the insulating layer 220 provided between theconductive layer 240 and the channel formation region. Formation of theconductive layer 240 in the position overlapping with the channelformation region of the oxide semiconductor layer can reduce the amountof shift in the threshold voltage of the thin film transistor 211 in aBT test. The potential of the conductive layer 240 may be the same as ordifferent from that of a gate electrode layer of the thin filmtransistor 211, and the conductive layer 240 can also function as asecond gate electrode layer of the thin film transistor 211.Alternatively, the potential of the conductive layer 240 may be GND or 0V, or the conductive layer 240 may be in a floating state.

Note that in this embodiment, an example where the thin film transistor210 and the thin film transistor 211 are bottom gate transistors isdescribed; however, this embodiment is not limited thereto, and a topgate transistor or a known transistor with another structure may beused.

The insulating layer 220 functions as a protective insulating layer ofthe oxide semiconductor layer. The insulating layer 220 is formed of asingle layer or a stacked layer including any of silicon oxide, siliconnitride, silicon oxynitride, and the like, by a sputtering method or thelike. The insulating layer 220 is formed, and after that, heat treatmentis preferably performed under an inert gas atmosphere or an oxygen gasatmosphere (preferably at greater than or equal to 200° C. and less thanor equal to 400° C., for example, at greater than or equal to 250° C.and less than or equal to 350° C.). The heat treatment can reducevariation in electric characteristics of the transistor. By the heattreatment, oxygen is supplied from the insulating layer including oxygento the oxide semiconductor layer; thus, defect level in an energy gapcaused by oxygen deficiency can also be reduced.

The insulating layer 221 functions as a planarization film for reducingroughness of the thin film transistor 210. The insulating layer 221 canbe formed using a heat-resistant organic material, such as polyimide,acrylic, benzocyclobutene, polyamide, or epoxy. Other than such organicmaterials, it is also possible to use a low-dielectric constant material(a low-k material), a siloxane-based resin, PSG (phosphosilicate glass),BPSG (borophosphosilicate glass), or the like. Note that the insulatinglayer 221 may be formed by stacking a plurality of insulating layersformed using any of these materials.

Note that the siloxane-based resin corresponds to a resin including aSi—O—Si bond formed using a siloxane-based material as a startingmaterial. The siloxane-based resin may include an organic group (e.g.,an alkyl group or an aryl group) or a fluoro group as a substituent. Inaddition, the organic group may include a fluoro group.

There is no particular limitation on the formation method of theinsulating layer 221, and the following can be employed depending on thematerial: a method such as a sputtering method, an SOG method, a spincoating, dip coating, spray coating, or a droplet discharging method(e.g., ink jetting, screen printing, or offset printing), or with a tool(equipment) such as a doctor knife, a roll coater, a curtain coater, ora knife coater. A baking step of the insulating layer 221 also serves asheat treatment of the oxide semiconductor layer; thus, a liquid crystaldisplay device can be manufactured efficiently.

In the case of a transmissive liquid crystal display device, for thepixel electrode layer 230, a light-transmitting conductive material suchas indium tin oxide (hereinafter referred to as ITO), indium zinc oxide,indium tin oxide to which silicon oxide is added, indium oxidecontaining tungsten oxide, indium zinc oxide containing tungsten oxide,indium oxide containing titanium oxide, or indium tin oxide containingtitanium oxide can be used. Note that for the conductive layer 240 thatis formed at the same time as the pixel electrode layer 230, theconductive material having a light transmitting property used for thepixel electrode layer 230 can be used.

The pixel electrode layer 230 can be formed using a conductivecomposition including a conductive high molecule (also referred to as aconductive polymer). The pixel electrode formed using the conductivecomposition preferably has a sheet resistance of less than or equal to10000 ohms per square and a light transmittance of greater than or equalto 70% at a wavelength of 550 nm. Further, the resistivity of theconductive high molecule included in the conductive composition ispreferably less than or equal to 0.1 Ω·cm. As the conductive highmolecule, a so-called π electron conjugated conductive high molecule canbe used. For example, polyaniline or a derivative thereof, polypyrroleor a derivative thereof, polythiophene or a derivative thereof, acopolymer of two or more kinds of them, and the like are given.

On the other hand, in the case of a reflective liquid crystal displaydevice, a metal electrode layer having high reflectivity is used as thepixel electrode layer 230. Specifically, aluminum, silver, or the likeis used. Further, the reflectivity is increased by making the surface ofthe pixel electrode layer 230 rough. Therefore, a base film of the pixelelectrode layer 230 may be made rough.

Further, in the case of a semi-transmissive liquid crystal displaydevice, a transmissive material and a reflective material are used forthe pixel electrode layer 230.

After the formation of the pixel electrode layer 230, surface treatmentmay be performed on the pixel electrode layer 230 by ultraviolet lightirradiation. The oxide semiconductor layer of the thin film transistor210 is damaged when the pixel electrode layer 230 is irradiated withultraviolet light; however, heat treatment performed later can repairdamage to the oxide semiconductor layer caused by ultraviolet lightirradiation.

The alignment film 232 can be formed using an organic resin such aspolyimide or polyvinyl alcohol or an inorganic material such as siliconoxide. After the formation of the alignment film 232, the alignment film232 is subjected to rubbing treatment so that liquid crystal moleculesto be formed in a later step are oriented at a certain pretilt angle.Note that in the case where the alignment film 232 is formed using aninorganic material such as silicon oxide, the alignment film 232 havingalignment characteristics can be formed by an evaporation method withoutrubbing treatment.

As the alignment film 232, an alignment film in which liquid crystal isaligned by ultraviolet light irradiation may be used. As such analignment film, a photosensitive resin such as polyvinylcinnamate (PVCi)or the like may be used. When such an alignment film is employed,rubbing treatment is unnecessary; thus, electrostatic discharge damagecaused by the rubbing treatment can be prevented and defects and damageof the liquid crystal display device can be reduced in the manufacturingprocess. The oxide semiconductor layer of the thin film transistor 210is damaged when the alignment film 232 is irradiated with ultravioletlight; however, heat treatment performed later can repair damage to theoxide semiconductor layer caused by ultraviolet light irradiation.

A method for manufacturing the counter substrate formed of the secondsubstrate 206 will be described here. The counter electrode layer 231 isformed over the second substrate 206, and the alignment film 233 isformed over the counter electrode layer 231. The second substrate 206,the counter electrode layer 231, and the alignment film 233 can beformed to have the same or substantially the same structure using thesame or substantially the same material as those of the first substrate201, the pixel electrode layer 230, and the alignment film 232,respectively.

The counter electrode layer 231 is electrically connected to a commonpotential line that is provided over the first substrate 201. Thecounter electrode layer 231 and the common potential line can beelectrically connected to each other using a common connecting portion,with conductive particles which are arranged between the pair ofsubstrates provided therebetween. Note that the conductive particles canbe contained in the sealant 205.

In FIG. 2, the spacer 235 is formed over the counter electrode layer 231using the counter substrate as a reference, but the spacer 235 may beformed over the alignment film 233. Alternatively, the spacer 235 may beformed over the alignment film 232 on the active matrix substrate side,not the counter substrate side. The spacer 235 is a columnar spacerobtained by selective etching of an insulating film and is provided inorder to control the distance (a cell gap) between the pixel electrodelayer 230 and the counter electrode layer 231. Note that a sphericalspacer may be used for the spacer 235.

Next, formation of the sealant (the step 102) will be described.

The sealant 205 is formed by a screen printing method, or using anink-jet apparatus or a dispensing apparatus so as to surround the pixelportion 202 and the driver circuit portion 204 (closed-loop shape) overthe first substrate 201. The sealant may be formed to have a rectangularshape, a circular shape, an elliptical shape, a polygonal shape, or thelike, as appropriate. The sealant 205 does not necessarily surround thedriver circuit portion 204 as long as it surrounds at least the pixelportion 202. For example, the sealant 205 may be formed so as tosurround part of the driver circuit portion 204; alternatively, thedriver circuit portion 204 may be formed outside the frame of thesealant 205. The sealant 205 may be formed in the driver circuit portion204 and thus a frame of the liquid crystal display device can benarrowed.

The sealant 205 is not necessarily formed over the first substrate 201and may be formed over the second substrate 206. In the case where thesealant 205 is formed over the second substrate 206, the sealant 205 isformed so that the sealant 205 over the second substrate 206 surroundsat least the pixel portion 202 when the first substrate 201 and thesecond substrate 206 are attached to each other in a later step.

The sealant 205 is preferably formed using a material including anultraviolet curable resin. As the ultraviolet curable resin, a resin inwhich an acrylic-based resin and an epoxy-based resin are mixed can beused. Further, a UV initiator, a thermosetting agent, a coupling agent,or the like may be mixed into the resin. Furthermore, a filler (1 μm to24 μm in diameter) may be contained. Note that it is preferable toselect as the sealant 205, a sealant which is insoluble in liquidcrystal with which the sealant 205 is in contact later.

After the formation of the sealant 205, the sealant 205 may betemporarily cured by ultraviolet light irradiation. The ultravioletlight irradiation for temporarily curing the sealant 205 is performedwith a low intensity for a short time as compared with ultraviolet lightirradiation for curing (fully curing) the sealant in a later step. Theultraviolet curable resin of the surface of the sealant 205 can behardened by temporarily curing the sealant 205; thus, when the liquidcrystal layer 208 is in contact with the sealant 205 in a later step, animpurity can be prevented from mixing with the liquid crystal layer 208from the sealant 205. Although the oxide semiconductor layers of thethin film transistor 211 and the thin film transistor 210 are damaged bythe ultraviolet light irradiation for temporarily curing the sealant205, such damage can be repaired by heat treatment performed in a laterstep.

Next, formation of the liquid crystal layer (the step 103) will bedescribed.

The liquid crystal layer 208 is formed by dropping liquid crystal in aregion surrounded by the sealant 205 formed over the first substrate 201or the second substrate 206 by a droplet discharging method such as adispensing method or an ink-jet method. Here, one drop of liquid crystalis dropped by an ODF method in the region surrounded by the sealant 205;however, this embodiment is not limited thereto and an appropriateamount of liquid crystal may be dropped in appropriate places in theregion surrounded by the sealant 205.

For the liquid crystal layer 208, nematic liquid crystal, cholestericliquid crystal, smectic liquid crystal, discotic liquid crystal,thermotropic liquid crystal, lyotropic liquid crystal, low-molecularliquid crystal, high-molecular liquid crystal, polymer dispersed liquidcrystal (PDLC), ferroelectric liquid crystal, anti-ferroelectric liquidcrystal, main-chain liquid crystal, side-chain high-molecular liquidcrystal, banana-shaped liquid crystal, or the like can be used.

The liquid crystal layer 208 is formed using liquid crystal including anultraviolet curable resin and the liquid crystal layer 208 may beapplied to a liquid crystal display device having a display modetypified by a polymer dispersed liquid crystal (PDLC) mode, a polymernetwork liquid crystal (PNLC) mode, or a blue phase mode.

A blue phase is one of liquid crystal phases, which is generated justbefore a cholesteric phase changes into an isotropic phase whentemperature of cholesteric liquid crystal is increased. A liquid crystalmaterial which exhibits a blue phase includes liquid crystal, a chiralagent, a photocurable resin, and a photopolymerization initiator. Thechiral agent is used to align the liquid crystal in a helical structureand to make the liquid crystal exhibit a blue phase. As an example, aliquid crystal material into which a chiral agent is mixed at 5 wt % ormore can be used. The liquid crystal material which includes liquidcrystal exhibiting a blue phase and a chiral agent has a short responsespeed of 1 msec or less and is optically isotropic; therefore, alignmenttreatment is not necessary and viewing angle dependence is small.Accordingly, the alignment films 232 and 233 do not need to be providedand thus rubbing treatment is not necessary. Thus, electrostaticdischarge damage caused by the rubbing treatment can be prevented anddefects and damage of the liquid crystal display device can be reducedin the manufacturing process, leading to an increase in productivity ofthe liquid crystal display device. A thin film transistor including anoxide semiconductor layer has the possibility that electricalcharacteristics of the thin film transistor may significantly change anddeviate from the designed range by the influence of static electricity.Therefore, it is more effective to use a blue-phase liquid crystalmaterial for a liquid crystal display in which a thin film transistorincluding an oxide semiconductor layer is used.

Next, attachment of the first substrate and the second substrate (thestep 104) will be described.

The liquid crystal layer 208 is formed in the region surrounded by thesealant 205, and after that, the first substrate 201 and the secondsubstrate 206 are attached to each other. The attachment of the firstsubstrate 201 and the second substrate 206 is preferably performed undera reduced-pressure atmosphere. This is because, even when the substratesare exposed to the atmosphere after attachment, a vacuum state can bekept in the inside of the sealant 205 and the liquid crystal layer 208can finally spread to end portions of the sealant 205 (the liquidcrystal can be formed in contact with the sealant 205). Note that in thecase where the sealant 205 and the liquid crystal layer 208 are formedover the second substrate 206, it is necessary that at least the pixelportion 202 of the first substrate 201 overlap with the liquid crystallayer 208.

In the case where liquid crystal exhibiting a blue phase is employed forthe liquid crystal layer 208, phase transition of the liquid crystallayer 208 from an isotropic phase to a blue phase and polymerstabilization treatment are preferably performed before curing of thesealant by ultraviolet light irradiation (the step 105). The phasetransition of the liquid crystal layer 208 from an isotropic phase to ablue phase is performed as follows: heat treatment is performed at atemperature within +10° C., preferably +5° C. from the phase transitiontemperature between the blue phase and the isotropic phase, and then thetemperature is gradually decreased. The phase transition temperaturebetween the blue phase and the isotropic phase is a temperature at whichthe phase changes from the blue phase to the isotropic phase when thetemperature rises, or a temperature at which the phase changes from theisotropic phase to the blue phase when the temperature decreases.

The polymer stabilization treatment can be performed in such a mannerthat a liquid crystal material including liquid crystal, a chiral agent,an ultraviolet curable resin, and a photopolymerization initiator isirradiated with light having a wavelength with which the ultravioletcurable resin and the photopolymerization initiator are reacted, in astate in which the blue phase is exhibited. The liquid crystal layer 208is irradiated with ultraviolet light in a state where temperature atwhich a blue phase is exhibited is kept; thus, the polymer stabilizationtreatment can be performed. The oxide semiconductor layers of the thinfilm transistors 210 and 211 are damaged when the liquid crystal layer208 is irradiated with ultraviolet light as the polymer stabilizationtreatment; however, heat treatment performed later can repair damage tothe oxide semiconductor layer caused by ultraviolet light irradiation.

Next, curing of the sealant by ultraviolet light irradiation (the step105) will be described.

The first substrate 201 and the second substrate 206 are attached toeach other, and then curing (fully curing) of the sealant 205 isperformed by ultraviolet light irradiation. The ultraviolet lightirradiation for fully curing the sealant 205 is performed with a highintensity for a long time as compared with ultraviolet light irradiationfor temporarily curing the sealant in the above-described step.Accordingly, the ultraviolet curable resin inside the sealant 205 can becured, which can increase adhesiveness between the first substrate 201and the second substrate 206. The oxide semiconductor layers of the thinfilm transistors 210 and 211 are damaged when the sealant 205 isirradiated with ultraviolet light to be cured; however, heat treatmentperformed later can repair damage to the oxide semiconductor layercaused by ultraviolet light irradiation.

After the ultraviolet light irradiation of the sealant 205, heattreatment is preferably performed on the sealant 205. Accordingly, thesealant 205 can be cured more firmly. The heat treatment for curing thesealant 205 is preferably formed at a temperature of 80° C. to 200° C.for 0.5 hours to 10 hours. Heat treatment of the sealant afterultraviolet light irradiation is effective because a portion which isshaded and not irradiated with ultraviolet light in the ultravioletlight irradiation can be cured by the heat treatment.

In the case where a polymer dispersed liquid crystal (PDLC) mode or apolymer network liquid crystal (PNLC) mode is used, it is preferablethat the ultraviolet light irradiation of the liquid crystal layer 208be performed at the same time as that of the sealant 205 so that theliquid crystal layer 208 is cured and droplets are formed in the liquidcrystal layer 208.

In the case where a plurality of panels is taken out from a pair ofsubstrates (obtaining a plurality of panels), the sealant 205 is curedand then, a pair of substrates which are attached is divided. The pairof substrates which are attached can be divided using a cuttingapparatus such as a scriber apparatus, a breaker apparatus, or a rollcutter.

When division is performed, the orientation of the liquid crystal layer208 which is aligned along the alignment films 232 and 233 is disorderedin some cases; thus, heat treatment for realigning the orientation ofthe liquid crystal layer 208 is preferably performed. Realignment of theliquid crystal layer 208 is performed in such a manner that heattreatment is performed at a temperature at which the liquid crystallayer 208 exhibits an isotropic phase or higher and the liquid crystallayer 208 is realigned when the temperature decreases. Heat treatmentfor realignment is preferably performed at a temperature of 80° C. to200° C. for 10 minutes to 60 minutes, preferably at a temperature of100° C. to 170° C. for 10 minutes to 60 minutes.

Lastly, heat treatment for repairing damage to the oxide semiconductorlayer caused by the ultraviolet light irradiation (the step 106) will bedescribed.

In the above-described process for manufacturing the liquid crystaldisplay device, ultraviolet light irradiation is performed in aplurality of steps, such as the step for curing the sealant 205including an ultraviolet curable resin. The oxide semiconductor layersof the thin film transistors 210 and 211 are irradiated with ultravioletlight that is direct light or reflected light, and the oxidesemiconductor layers are damaged by the ultraviolet light. Accordingly,electric characteristics of a thin film transistor including the oxidesemiconductor layer damaged by the ultraviolet light are decreased. Inparticular, the threshold voltage of the thin film transistor greatlyshifts in the negative direction, a current tends to flow between asource electrode and a drain electrode even when the gate voltage is 0V; in other words, the thin film transistor tends to be normally on.

In order to suppress such shift of the threshold voltage of the thinfilm transistor in the negative direction, after all the steps ofultraviolet light irradiation are completed in the process formanufacturing the liquid crystal display device, heat treatment forrepairing damage to the oxide semiconductor layer caused by ultravioletlight irradiation is performed.

The heat treatment for repairing damage to the oxide semiconductor layeris performed preferably at a temperature of 50° C. to 300° C. for 0.5hours to 24 hours, further preferably at a temperature of 125° C. to250° C. for 1 hour to 15 hours. In addition, the heat treatment ispreferably performed under an air atmosphere, an oxygen atmosphere, anitrogen atmosphere, or a rare gas (such as helium, neon, or argon)atmosphere. The temperature of the heat treatment for repairing damageto the oxide semiconductor layer is preferably lower than that of theheat treatment for dehydration or dehydrogenation of the oxidesemiconductor layer. A heating method using an electric furnace or thelike can be employed for the heat treatment for repairing damage to theoxide semiconductor layer.

Realignment of atoms which exist in the oxide semiconductor layer or inthe vicinity thereof is gradually carried out by the heat treatment.According to this, it is possible to repair dangling bonds formed byultraviolet light irradiation in the oxide semiconductor layer, at theinterface between the oxide semiconductor layer and the gate insulatinglayer, or at the interface between the oxide semiconductor layer and theinsulating layer 220.

Damage to the oxide semiconductor layer by ultraviolet light can berepaired, so that a decrease in electric characteristics of the thinfilm transistor including the oxide semiconductor layer can be preventedand the shift of the threshold voltage in the negative direction can besuppressed.

In addition, even when the threshold voltage varies among thin filmtransistors formed over one substrate by ultraviolet light irradiation,the above-described heat treatment can reduce the variation in thethreshold voltage.

The channel length of the thin film transistor is shortened, so thathigh speed operation and low power consumption of the liquid crystaldisplay device can be achieved.

The heat treatment for repairing damage to the oxide semiconductor layercan also serve as heat treatment for curing the sealant 205 which isperformed after ultraviolet light irradiation of the sealant 205.

As described above, the liquid crystal display device is manufactured bythe method described in this embodiment, so that damage to an oxidesemiconductor layer caused by ultraviolet light irradiation can berepaired. According to this, even when the oxide semiconductor layer ofthe thin film transistor included in the liquid crystal display deviceis damaged by ultraviolet light in the process for manufacturing theliquid crystal display device, shift of the threshold voltage of thethin film transistor in the negative direction due to the damage byultraviolet light irradiation can be suppressed.

Moreover, the thin film transistor that functions as a switching elementin the display device can be normally off, so that the liquid crystaldisplay device having low power consumption and high reliability can bemanufactured.

Embodiment 2

In this embodiment, a method for manufacturing a liquid crystal displaydevice illustrated in FIG. 2, in which a thin film transistor includingan oxide semiconductor layer is used, will be described with referenceto a flow chart of FIG. 3. The flow chart of FIG. 3 shows steps formanufacturing the liquid crystal display device illustrated in FIG. 2 bya liquid crystal injection method.

In this embodiment, in accordance with the flow chart of FIG. 3,formation of a thin film transistor including an oxide semiconductorlayer (a step 121), formation of a sealant (a step 122), attachment of afirst substrate and a second substrate (a step 123), curing of thesealant by ultraviolet light irradiation (a step 124), formation of aliquid crystal layer by injection (a step 125), and heat treatment forrepairing damage to the oxide semiconductor layer caused by theultraviolet light irradiation (a step 126) will be described in thisorder. Note that the structure of the liquid crystal display deviceillustrated in FIG. 2 is the same as that described in Embodiment 1;therefore, Embodiment 1 is to be referred to.

Formation of the thin film transistor including an oxide semiconductorlayer (the step 121) is the same or substantially the same as theformation of the thin film transistor including an oxide semiconductorlayer (the step 101) described in Embodiment 1; therefore, Embodiment 1is to be referred to.

Next, formation of the sealant (the step 122) will be described.

The sealant 205 is formed by a screen printing method, or using anink-jet apparatus or a dispensing apparatus so as to surround the pixelportion 202 and the driver circuit portion 204 over the first substrate201. In order to inject liquid crystal in a later step into the regionsurrounded by the sealant 205, an opening for injection of liquidcrystal is formed in part of the sealant 205. The sealant may be formedto have a rectangular shape, a circular shape, an elliptical shape, apolygonal shape, or the like, as appropriate. The sealant 205 does notnecessarily surround the driver circuit portion 204 as long as itsurrounds at least the pixel portion 202. For example, the sealant 205may be formed so as to surround part of the driver circuit portion 204;alternatively, the driver circuit portion 204 may be formed outside theframe of the sealant 205. The sealant 205 may be formed in the drivercircuit portion 204 and thus a frame of the liquid crystal displaydevice can be narrowed.

The sealant 205 is not necessarily formed over the first substrate 201and may be formed over the second substrate 206. In the case where thesealant 205 is formed over the second substrate 206, the sealant 205 isformed so that the sealant 205 over the second substrate 206 surroundsat least the pixel portion 202 when the first substrate 201 and thesecond substrate 206 are attached to each other in a later step.

The sealant 205 is preferably formed using a material including anultraviolet curable resin, and the material can be the same orsubstantially the same as the material described in Embodiment 1.

After the formation of the sealant 205, the sealant 205 may betemporarily cured by ultraviolet light irradiation. The ultravioletlight irradiation for temporarily curing the sealant 205 is performedwith a low intensity for a short time as compared with ultraviolet lightirradiation for curing (fully curing) the sealant in a later step. Theultraviolet curable resin of the surface of the sealant 205 can behardened by temporarily curing the sealant 205; thus, when the liquidcrystal layer 208 is in contact with the sealant 205 in a later step, animpurity can be prevented from mixing with the liquid crystal layer 208from the sealant 205. Although the oxide semiconductor layers of thethin film transistor 211 and the thin film transistor 210 are damaged bythe ultraviolet light irradiation for temporarily curing the sealant205, such damage can be repaired by heat treatment performed in a laterstep.

Next, attachment of the first substrate and the second substrate (thestep 123) will be described.

The first substrate 201 and the second substrate 206 are attached toeach other under a reduced-pressure atmosphere in a manner similar tothat of attachment of the first substrate and the second substrate (thestep 104) in Embodiment 1.

Next, curing of the sealant by ultraviolet light irradiation (the step124) will be described.

The first substrate 201 and the second substrate 206 are attached toeach other in a manner similar to that of curing of the sealant byultraviolet light irradiation (the step 105) in Embodiment 1, and thencuring (fully curing) of the sealant 205 is performed by ultravioletlight irradiation. The ultraviolet light irradiation for fully curingthe sealant 205 is performed with a high intensity for a long time ascompared with ultraviolet light irradiation for temporarily curing thesealant in the above-described step. Accordingly, the ultravioletcurable resin inside the sealant 205 can be cured, which can increaseadhesiveness between the first substrate 201 and the second substrate206. The oxide semiconductor layers of the thin film transistors 210 and211 are damaged when the sealant 205 is irradiated with ultravioletlight to be cured; however, heat treatment performed later can repairdamage to the oxide semiconductor layer caused by ultraviolet lightirradiation.

After the ultraviolet light irradiation of the sealant 205, heattreatment is preferably performed on the sealant 205. Accordingly, thesealant 205 can be cured more firmly. The heat treatment for curing thesealant 205 is preferably formed at a temperature of 80° C. to 200° C.for 0.5 hours to 10 hours. Heat treatment of the sealant afterultraviolet light irradiation is effective because a portion which isshaded and not irradiated with ultraviolet light in the ultravioletlight irradiation can be cured by the heat treatment.

In the case where a plurality of panels is taken out from a pair ofsubstrates (obtaining a plurality of panels), the sealant 205 is curedand then, a pair of substrates which are attached is divided. At thistime, the pair of substrates attached to each other is divided so thatthe opening formed in the sealant 205 is exposed. The pair of substrateswhich are attached can be divided using a cutting apparatus such as ascriber apparatus, a breaker apparatus, or a roll cutter.

Next, formation of the liquid crystal layer by injection (the step 125)will be described.

The liquid crystal layer 208 is formed in such a manner that liquidcrystal is injected in a region surrounded by the sealant 205 formedover the first substrate 201 or the second substrate 206 by a liquidcrystal injection method such as a vacuum injection method. For example,in the case of employing a vacuum injection method, the pair ofsubstrates attached to each other is put in a vacuum chamber, and thenliquid crystal is in contact with the opening formed in the sealant 205of the pair of substrates attached to each other in a vacuum. Afterthat, a gas is supplied to the vacuum chamber and the pressure in thevacuum chamber is increased; thus, liquid crystal is injected into theregion surrounded by the sealant 205 through the opening. After theinjection of liquid crystal, the opening of the sealant 205 is sealedwith an ultraviolet curable resin or the like.

The liquid crystal layer 208 can be the same or substantially the sameas the layer described in Embodiment 1.

The liquid crystal layer 208 is formed using liquid crystal including anultraviolet curable resin in a manner similar to that in Embodiment 1and the liquid crystal layer 208 may be applied to a liquid crystaldisplay device having a display mode typified by a PDLC mode, a PNLCmode, or a blue phase mode.

A thin film transistor including an oxide semiconductor layer has thepossibility that electrical characteristics of the thin film transistormay significantly change and deviate from the designed range by theinfluence of static electricity. Therefore, it is more effective to usea blue-phase liquid crystal material for a liquid crystal display devicehaving a thin film transistor including an oxide semiconductor layer.

In the case where liquid crystal exhibiting a blue phase is employed asthe liquid crystal layer 208, phase transition of the liquid crystallayer 208 from an isotropic phase to a blue phase and polymerstabilization treatment are performed. The phase transition of theliquid crystal layer 208 from an isotropic phase to a blue phase isperformed as follows: heat treatment is performed at a temperaturewithin +10° C., preferably +5° C. from the phase transition temperaturebetween the blue phase and the isotropic phase, and then the temperatureis gradually decreased. The phase transition temperature between theblue phase and the isotropic phase is a temperature at which the phasechanges from the blue phase to the isotropic phase when the temperaturerises, or a temperature at which the phase changes from the isotropicphase to the blue phase when the temperature decreases.

The polymer stabilization treatment can be performed in such a mannerthat a liquid crystal material including liquid crystal, a chiral agent,an ultraviolet curable resin, and a photopolymerization initiator isirradiated with light having a wavelength with which the ultravioletcurable resin and the photopolymerization initiator are reacted, in astate in which the blue phase is exhibited. The liquid crystal layer 208is irradiated with ultraviolet light in a state where temperature atwhich a blue phase is exhibited is kept; thus, the polymer stabilizationtreatment can be performed. The oxide semiconductor layers of the thinfilm transistors 210 and 211 are damaged when the liquid crystal layer208 is irradiated with ultraviolet light as the polymer stabilizationtreatment; however, heat treatment performed later can repair damage tothe oxide semiconductor layer caused by ultraviolet light irradiation.

In the case where a polymer dispersed liquid crystal (PDLC) mode or apolymer network liquid crystal (PNLC) mode is used, ultraviolet lightirradiation of the liquid crystal layer 208 is performed so that theliquid crystal layer 208 is cured and droplets are formed in the liquidcrystal layer 208.

After the liquid crystal layer 208 is formed by a liquid crystalinjection method, the orientation of the liquid crystal is disordered insome cases; thus, heat treatment for realigning the orientation of theliquid crystal layer 208 is preferably performed. Realignment of theliquid crystal layer 208 is performed in such a manner that heattreatment is performed at a temperature at which the liquid crystallayer 208 exhibits an isotropic phase or higher and the liquid crystallayer 208 is realigned when the temperature decreases. Heat treatmentfor realignment is preferably performed at a temperature of 80° C. to200° C. for 10 minutes to 60 minutes, preferably at a temperature of100° C. to 170° C. for 10 minutes to 60 minutes.

Lastly, heat treatment for repairing damage to the oxide semiconductorlayer caused by the ultraviolet light irradiation (the step 126) will bedescribed.

In order to suppress shift of the threshold voltage of the thin filmtransistor in the negative direction, after all the steps of ultravioletlight irradiation are completed in the process for manufacturing theliquid crystal display device, heat treatment for repairing damage tothe oxide semiconductor layer caused by ultraviolet light irradiation isperformed, in a manner similar to that of Embodiment 1.

The heat treatment for repairing damage to the oxide semiconductor layeris performed preferably at a temperature of 50° C. to 300° C. for 0.5hours to 24 hours, further preferably at a temperature of 125° C. to250° C. for 2 hours to 15 hours. In addition, the heat treatment ispreferably performed under an air atmosphere, an oxygen atmosphere, anitrogen atmosphere, or a rare gas (such as helium, neon, or argon)atmosphere. The heat treatment for repairing damage to the oxidesemiconductor layer is preferably performed at a lower temperature forlonger time as compared with the heat treatment for formation of theoxide semiconductor layer. A heating method using an electric furnace orthe like can be employed for the heat treatment for repairing damage tothe oxide semiconductor layer.

Realignment of atoms which exist in the oxide semiconductor layer or inthe vicinity thereof is gradually carried out by the heat treatment.According to this, it is possible to repair dangling bonds formed byultraviolet light irradiation in the oxide semiconductor layer, at theinterface between the oxide semiconductor layer and the gate insulatinglayer, or at the interface between the oxide semiconductor layer and theinsulating layer 220.

Damage to the oxide semiconductor layer by ultraviolet light can berepaired, so that a decrease in electric characteristics of the thinfilm transistor including the oxide semiconductor layer can be preventedand the shift of the threshold voltage in the negative direction can besuppressed.

In addition, even when the threshold voltage varies among thin filmtransistors formed over one substrate by ultraviolet light irradiation,the above-described heat treatment can reduce the variation in thethreshold voltage.

The channel length of the thin film transistor is shortened, so thathigh speed operation and low power consumption of the liquid crystaldisplay device can be achieved.

The heat treatment for repairing damage to the oxide semiconductor layercan also serve as the heat treatment for realignment.

As described above, the liquid crystal display device is manufactured bythe method described in this embodiment, so that damage to an oxidesemiconductor layer caused by ultraviolet light irradiation can berepaired. According to this, even when the oxide semiconductor layer ofthe thin film transistor included in the liquid crystal display deviceis damaged by ultraviolet light in the process for manufacturing theliquid crystal display device, shift of the threshold voltage of thethin film transistor in the negative direction due to the damage byultraviolet light irradiation can be suppressed.

Moreover, the thin film transistor that functions as a switching elementin the display device can be normally off, so that the liquid crystaldisplay device having low power consumption and high reliability can bemanufactured.

Embodiment 3

In this embodiment, a method for manufacturing a light-emitting displaydevice illustrated in FIG. 5, in which a thin film transistor includingan oxide semiconductor layer is used, will be described with referenceto a flow chart of FIG. 4.

In this embodiment, as a display element included in a display device, alight-emitting element utilizing electroluminescence is used.Light-emitting elements utilizing electroluminescence are classifiedaccording to whether a light-emitting material is an organic compound oran inorganic compound. In general, the former is referred to as anorganic EL element, and the latter is referred to as an inorganic ELelement.

In an organic EL element, by application of voltage to a light-emittingelement, electrons and holes are separately injected from a pair ofelectrodes into a layer containing a light-emitting organic compound,and current flows. The carriers (electrons and holes) are recombined,and thus, the light-emitting organic compound is excited. Thelight-emitting organic compound returns to a ground state from theexcited state, thereby emitting light. Owing to such a mechanism, thislight-emitting element is referred to as a current-excitationlight-emitting element.

The inorganic EL elements are classified according to their elementstructures into a dispersion-type inorganic EL element and a thin-filminorganic EL element. A dispersion-type inorganic EL element has alight-emitting layer where particles of a light-emitting material aredispersed in a binder, and its light emission mechanism isdonor-acceptor recombination type light emission that utilizes a donorlevel and an acceptor level. A thin-film inorganic EL element has astructure where a light-emitting layer is sandwiched between dielectriclayers, which are further sandwiched between electrodes, and its lightemission mechanism is localized type light emission that utilizesinner-shell electron transition of metal ions. Note that in thisembodiment, description is made using an organic EL element as alight-emitting element.

A structure of a light-emitting display device illustrated in FIG. 5will be described. In the light-emitting display device, a thin filmtransistor 310, a thin film transistor 311, and a light-emitting element313 which are formed over a first substrate 301 are sealed between thefirst substrate 301 and a second substrate 306 with a sealant 305. Aspace between the thin film transistor 310, the thin film transistor311, and the light-emitting element 313 and the second substrate 306 isfilled with a filler to form a filler material layer 308. It ispreferable that the light-emitting element 313 be thus packaged (sealed)with a protective film (such as an attachment film or an ultravioletcurable resin film) or a cover material with high air-tightness andlittle degasification so that the light-emitting element 313 is notexposed to the outside air.

The light-emitting display device illustrated in FIG. 5 has thefollowing structure on the active matrix substrate side. Over the firstsubstrate 301, a thin film transistor 310 including an oxidesemiconductor layer is formed in a pixel portion 302 and a thin filmtransistor 311 including an oxide semiconductor layer is formed in adriver circuit portion 304. An insulating layer 320 and an insulatinglayer 321 are formed over the thin film transistor 310 in the pixelportion 302, a first electrode layer 330 electrically connected to oneof a source electrode layer and a drain electrode layer of the thin filmtransistor is formed over the insulating layer 321, and a partition 335is formed over the first electrode layer 330 and the insulating layer321. An electroluminescent layer 332 is formed over the partition 335and the first electrode layer 330, and a second electrode layer 334 isformed over the electroluminescent layer 332. The light-emitting element313 is formed by stacking the first electrode layer 330, theelectroluminescent layer 332, and the second electrode layer 334. Notethat the structure of the light-emitting element 313 is not limitedthereto. The structure of the light-emitting element 313 can be changedas appropriate depending on the direction in which light is extractedfrom the light-emitting element 313, or the like. Further, a conductivelayer 340 is formed over the thin film transistor 311 in the drivercircuit portion 304.

Note that in this embodiment, the driver circuit portion 304 is formedinside the frame of the sealant 305; however, the driver circuit portion304 is not necessarily formed in such a manner, and the entire or partof the driver circuit portion 304 may be formed outside the frame of thesealant 305. In the case of forming the driver circuit portion outsidethe frame of the sealant 305, the driver circuit portion may be formedover another substrate, and then mounted by a COG method, a wire bondingmethod, a TAB method or the like. For example, a scan line drivercircuit portion may be formed with a pixel portion inside the frame ofthe sealant over one substrate and a signal line driver circuit portionmay be formed over another substrate, and then mounted over the activematrix substrate.

Next, in accordance with the flow chart of FIG. 4, a method formanufacturing the light-emitting display device illustrated in FIG. 5will be described.

In this embodiment, in accordance with the flow chart of FIG. 4,formation of a thin film transistor including an oxide semiconductorlayer (a step 131), formation of a light-emitting element (a step 132),formation of a sealant (a step 133), attachment of a first substrate anda second substrate (a step 134), curing of the sealant by ultravioletlight irradiation (a step 135), and heat treatment for repairing damageto the oxide semiconductor layer caused by the ultraviolet lightirradiation (a step 136) will be described in this order.

Formation of the thin film transistor including an oxide semiconductorlayer (the step 131) is the same or substantially the same as theformation of the thin film transistor including an oxide semiconductorlayer (the step 101) described in Embodiment 1; therefore, Embodiment 1is to be referred to. Materials and methods for manufacturing the firstsubstrate 301, the second substrate 306, the thin film transistor 310,the thin film transistor 311, the conductive layer 340, the insulatinglayer 320, and the insulating layer 321 are the same or substantiallythe same as the materials and methods for manufacturing the firstsubstrate 201, the second substrate 206, the thin film transistor 210,the thin film transistor 211, the conductive layer 240, the insulatinglayer 220, and the insulating layer 221 described in Embodiment 1,respectively; therefore, Embodiment 1 is to be referred to.

Next, formation of the light-emitting element (the step 132) will bedescribed. An opening is formed by etching the insulating layer 321 soas to reach one of the source electrode and the drain electrode of thethin film transistor 310. After that, the first electrode layer 330 isformed; the partition 335 is formed to have an opening over the firstelectrode layer 330; and the electroluminescent layer 332 and the secondelectrode layer 334 are formed over the partition 335 and the firstelectrode layer 330. Accordingly, the light-emitting element 313 formedby stacking the first electrode layer 330, the electroluminescent layer332, and the second electrode layer 334 can be formed. Described belowis combination of materials for the first electrode layer 330 thatserves as a cathode and a second electrode layer 334 that serves as ananode in the case of the top-emission structure in which light isemitted from the light-emitting element 313 to the second electrodelayer 334.

The first electrode layer 330 that functions as a cathode can be formedusing a variety of materials, and a material having a low work function,for example, an alkali metal such as Li or Cs, an alkaline earth metalsuch as Mg, Ca, or Sr, an alloy including any of these (such as Mg:Ag orAl:Li), a rare earth metal such as Yb or Er, or the like is preferablyused.

The partition 335 for insulating the first electrode layer 330 of anadjacent pixel is formed using an organic resin film such as polyimide,acrylic, polyamide, or epoxy; an inorganic insulating film; or organicpolysiloxane. It is particularly preferable that the partition 335 beformed using a photosensitive resin material to have an opening over thefirst electrode layer 330 so that a sidewall of the opening is formed asa tilted surface with continuous curvature. In the case of using aphotosensitive resin material for the partition 335, a step of forming aresist mask can be omitted. The oxide semiconductor layer of the thinfilm transistor 310 is damaged when the partition 335 is irradiated withultraviolet light; however, heat treatment performed later can repairdamage to the oxide semiconductor layer caused by ultraviolet lightirradiation.

The electroluminescent layer 332 may be formed using a single layer or aplurality of layers stacked. In the case where the electroluminescentlayer 332 is formed using a plurality of layers, an electron-injectionlayer, an electron-transport layer, a light-emitting layer, ahole-transport layer, and a hole-injection layer are stacked in thisorder over the first electrode layer 330 that functions as a cathode. Itis not necessary to form all of these layers.

The second electrode layer 334 that functions as an anode is formedusing a light-transmitting conductive material. For example, alight-transmitting conductive film of indium oxide including tungstenoxide, indium zinc oxide including tungsten oxide, indium oxideincluding titanium oxide, indium tin oxide including titanium oxide,indium tin oxide, indium zinc oxide, or indium tin oxide to whichsilicon oxide is added may be used.

In the case of a bottom-emission structure in which light is emittedfrom the light-emitting element 313 to the first electrode layer 330 ora dual-emission structure in which light is emitted from thelight-emitting element 313 to the first electrode layer 330 and thesecond electrode layer 334, a structure such that emission from thelight-emitting element 313 is not prevented; for example, a reflectiveconductive film may be provided or materials may be exchanged betweenthe electrode layers as appropriate.

Next, formation of the sealant (the step 133) will be described.

The sealant 305 is formed by a screen printing method, or using anink-jet apparatus or a dispensing apparatus so as to surround the pixelportion 302 and the driver circuit portion 304 (closed-loop shape) overthe first substrate 301. The sealant may be formed to have a rectangularshape, a circular shape, an elliptical shape, a polygonal shape, or thelike, as appropriate. The sealant 305 does not necessarily surround thedriver circuit portion 304 as long as it surrounds at least the pixelportion 302. For example, the sealant 305 may be formed so as tosurround part of the driver circuit portion 304; alternatively, thedriver circuit portion 304 may be formed outside the frame of thesealant 305. The sealant 305 may be formed in the driver circuit portion304 and thus a frame of the light-emitting display device can benarrowed.

The sealant 305 is not necessarily formed over the first substrate 301and may be formed over the second substrate 306. In the case where thesealant 305 is formed over the second substrate 306, the sealant 305 isformed so that the sealant 305 over the second substrate 306 surroundsat least the pixel portion 302 when the first substrate 301 and thesecond substrate 306 are attached to each other in a later step.

The sealant 305 is preferably formed using a material including anultraviolet curable resin. As the ultraviolet curable resin, a resin inwhich an acrylic-based resin and an epoxy-based resin are mixed can beused. Further, a UV initiator, a thermosetting agent, a coupling agent,or the like may be mixed into the resin. Furthermore, a filler (1 μm to24 μm in diameter) may be contained.

The sealant 305 is formed, and then the sealant 305 may be irradiatedwith ultraviolet light to be temporarily cured. The ultraviolet lightirradiation for temporarily curing the sealant 305 is performed with alow intensity for a short time as compared with ultraviolet lightirradiation for curing (fully curing) the sealant in a later step. Theoxide semiconductor layers of thin film transistors 310 and 311 aredamaged when the sealant 305 is irradiated with ultraviolet light to betemporarily cured; however, heat treatment performed later can repairdamage to the oxide semiconductor layer caused by ultraviolet lightirradiation.

In the case where a space between the active matrix substrate and thesecond substrate 306 is filled with the filler, the filling may beperformed after the formation of the sealant 305. The filler materiallayer 308 is formed by dropping the filler in a region surrounded by thesealant 305 formed over the first substrate 301 or the second substrate306 by a droplet discharging method such as a dispensing method or anink-jet method. As the filler, an ultraviolet curable resin or athermosetting resin can be used; for example, polyvinyl chloride (PVC),acrylic, polyimide, an epoxy resin, a silicone resin, polyvinyl butyral(PVB), or ethylene vinyl acetate (EVA) can be used. In the case of usingan ultraviolet curable resin as the filler, the sealant 305 is notnecessarily used because the first substrate 301 and the secondsubstrate 306 can be in close contact with each other using the fillermaterial layer 308.

In the case of using an ultraviolet curable resin as the filler, theoxide semiconductor layers of thin film transistors 310 and 311 aredamaged by ultraviolet light irradiation for curing; however, heattreatment performed later can repair damage to the oxide semiconductorlayer caused by ultraviolet light irradiation.

Alternatively, as the filler, a space between the active matrixsubstrate and the second substrate 306 may be filled with an inert gassuch as nitrogen or argon.

Next, attachment of the first substrate and the second substrate (thestep 134) will be described.

The sealant 305 is formed so as to surround the pixel portion 302 andthe driver circuit portion 304 (closed-loop shape), and then the firstsubstrate 301 and the second substrate 306 are attached to each other.Note that in the case where the sealant 305 and the filler materiallayer 308 are formed over the second substrate 306, it is necessary thatat least the pixel portion 302 of the first substrate 301 overlap withthe filler material layer 308.

Alternatively, after the first substrate 301 and the second substrate306 are attached to each other, the filler material layer 308 may beformed. In that case, an opening is formed in the sealant 305 when thesealant 305 is formed, and a space between the active matrix substrateand the second substrate 306 is filled with the filler by a vacuuminjection method or the like.

Next, curing of the sealant by ultraviolet light irradiation (the step135) will be described.

The first substrate 301 and the second substrate 306 are attached toeach other, and then curing (fully curing) of the sealant 305 isperformed by ultraviolet light irradiation. The ultraviolet lightirradiation for fully curing the sealant 305 is performed with a highintensity for a long time as compared with ultraviolet light irradiationfor temporarily curing the sealant in the above-described step.Accordingly, the ultraviolet curable resin inside the sealant 305 can becured, which can increase adhesiveness between the first substrate 301and the second substrate 306. The oxide semiconductor layers of the thinfilm transistors 310 and 311 are damaged when the sealant 305 isirradiated with ultraviolet light to be cured; however, heat treatmentperformed later can repair damage to the oxide semiconductor layercaused by ultraviolet light irradiation.

After the ultraviolet light irradiation of the sealant 305, heattreatment is preferably performed on the sealant 305. Accordingly, thesealant 305 can be cured more firmly. The heat treatment for curing thesealant 305 is preferably formed at a temperature of 80° C. to 200° C.for 0.5 hours to 10 hours. Heat treatment of the sealant afterultraviolet light irradiation is effective because a portion which isshaded and not irradiated with ultraviolet light in the ultravioletlight irradiation can be cured by the heat treatment.

In the case of using an ultraviolet curable resin as the filler, thefiller can be cured together with the sealant 305.

In the case where a plurality of panels is taken out from a pair ofsubstrates (obtaining a plurality of panels), the sealant 305 is curedand then, a pair of substrates which are attached is divided. The pairof substrates which are attached can be divided using a cuttingapparatus such as a scriber apparatus, a breaker apparatus, or a rollcutter.

Lastly, heat treatment for repairing damage to the oxide semiconductorlayer caused by the ultraviolet light irradiation (the step 136) will bedescribed.

In order to suppress shift of the threshold voltage of the thin filmtransistor in the negative direction, after all the steps of ultravioletlight irradiation are completed in the process for manufacturing thelight-emitting display device, heat treatment for repairing damage tothe oxide semiconductor layer caused by ultraviolet light irradiation isperformed in a manner similar to that in Embodiment 1 or Embodiment 2.

The heat treatment for repairing damage to the oxide semiconductor layeris performed preferably at a temperature of 50° C. to 300° C. for 0.5hours to 24 hours, further preferably at a temperature of 125° C. to250° C. for 1 hour to 15 hours. In addition, the heat treatment ispreferably performed under an air atmosphere, an oxygen atmosphere, anitrogen atmosphere, or a rare gas (such as helium, neon, or argon)atmosphere. The temperature of the heat treatment for repairing damageto the oxide semiconductor layer is preferably lower than that of theheat treatment for dehydration or dehydrogenation of the oxidesemiconductor layer. A heating method using an electric furnace or thelike can be employed for the heat treatment for repairing damage to theoxide semiconductor layer.

Realignment of atoms which exist in the oxide semiconductor layer or inthe vicinity thereof is gradually carried out by the heat treatment.According to this, it is possible to repair dangling bonds formed byultraviolet light irradiation in the oxide semiconductor layer, at theinterface between the oxide semiconductor layer and the gate insulatinglayer, or at the interface between the oxide semiconductor layer and theinsulating layer 320.

Damage to the oxide semiconductor layer by ultraviolet light can berepaired, so that a decrease in electric characteristics of the thinfilm transistor including the oxide semiconductor layer can be preventedand the shift of the threshold voltage in the negative direction can besuppressed.

In addition, even when the threshold voltage varies among thin filmtransistors formed over one substrate by ultraviolet light irradiation,the above-described heat treatment can reduce the variation in thethreshold voltage.

The channel length of the thin film transistor is shortened, so thathigh speed operation and low power consumption of the light-emittingdisplay device can be achieved.

The heat treatment for repairing damage to the oxide semiconductor layercan also serve as heat treatment for curing the sealant 305 which isperformed after ultraviolet light irradiation of the sealant 305.

As described above, the light-emitting display device is manufactured bythe method described in this embodiment, so that damage to an oxidesemiconductor layer caused by ultraviolet light irradiation can berepaired. According to this, even when the oxide semiconductor layer ofthe thin film transistor included in the light-emitting display deviceis damaged by ultraviolet light in the process for manufacturing thelight-emitting display device, shift of the threshold voltage of thethin film transistor in the negative direction due to the damage byultraviolet light irradiation can be suppressed.

Moreover, the thin film transistor that functions as a switching elementin the display device can be normally off, so that the light-emittingdisplay device having low power consumption and high reliability can bemanufactured.

Embodiment 4

In this embodiment, a method for manufacturing an electrophoreticdisplay device illustrated in FIG. 7, in which a thin film transistorincluding an oxide semiconductor layer is used, will be described withreference to a flow chart of FIG. 6.

The method for manufacturing the display device described in Embodiment1 may be used for an electrophoretic display device in which electronicink is driven by utilizing an element electrically connected to aswitching element. The electrophoretic display device is also called anelectrophoretic display and has advantages that it has the same level ofreadability as paper, and it consumes less power and is thinner andlighter than other display devices.

There are a variety of modes of electrophoretic displays. Theelectrophoretic display is a device in which a plurality ofmicrocapsules each including first particles having positive charge andsecond particles having negative charge are dispersed in a solvent or asolute, and an electrical field is applied to the microcapsules so thatthe particles in the microcapsules move in opposite directions from eachother, and only a color of the particles gathered on one side isdisplayed. Note that the first particles or the second particles includea colorant, and does not move when there is not electric field. A colorof the first particles is different from a color of the second particles(the particles may also be colorless).

Thus, the electrophoretic display utilizes a so-called dielectrophoreticeffect, in which a substance with high dielectric constant moves to aregion with high electric field.

A substance in which the microcapsules are dispersed in a solvent iscalled electronic ink, and this electronic ink can be printed on asurface of glass, plastic, fabric, paper, or the like. Color display isalso possible with the use of a color filter or particles including acoloring matter.

In addition, an active matrix display device can be completed byproviding as appropriate, a plurality of the microcapsules over anactive matrix substrate so as to be interposed between two electrodes,and can perform display by application of electric field to themicrocapsules.

Note that the first particles and the second particles in themicrocapsule may be formed from one of a conductive material, aninsulating material, a semiconductor material, a magnetic material, aliquid crystal material, a ferroelectric material, an electroluminescentmaterial, an electrochromic material, and a magnetophoretic material ora composite material thereof.

The electrophoretic display device illustrated in FIG. 7 is an exampleof an electrophoretic display device using a twisting ball displaysystem. The twisting ball display system refers to a method in whichspherical particles each colored in black and white are arranged betweena first electrode layer and a second electrode layer which are electrodelayers used for a display element, and a potential difference isgenerated between the first electrode layer and the second electrodelayer to control orientation of the spherical particles, so that displayis performed.

The display system of an electrophoretic display device is not limitedthereto; microcapsule electrophoresis system, Microcup (registeredtrademark) electrophoresis system, the horizontal electrophoresissystem, the vertical electrophoresis system, a particle-moving system,Electronic Liquid Powder (registered trademark) system, a system usingcholesteric liquid crystal, a system using chiral nematic liquidcrystal, a system using anti-ferroelectric liquid crystal, a systemusing polymer dispersed liquid crystal, a system using a charged toner,an electrowetting system, an electrochromism system, anelectrodeposition system, or the like may be employed.

A structure of the electrophoretic display device illustrated in FIG. 7will be described. In the electrophoretic display device, anelectrophoretic display element layer 413 is sandwiched between anactive matrix substrate formed of a first substrate 401 and a secondsubstrate 406. Further, a sealant 405 is formed so as to surround apixel portion 402 and a driver circuit portion 404 between the firstsubstrate 401 and the second substrate 406.

The electrophoretic display device illustrated in FIG. 7 has thefollowing structure on the active matrix substrate side. Over the firstsubstrate 401, a thin film transistor 410 including an oxidesemiconductor layer is formed in a pixel portion 402 and a thin filmtransistor 411 including an oxide semiconductor layer is formed in adriver circuit portion 404. An insulating layer 420 and an insulatinglayer 421 are formed over the thin film transistor 410 in the pixelportion 402, and a first electrode layer 430 electrically connected toone of a source electrode layer and a drain electrode layer of the thinfilm transistor is formed over the insulating layer 421. Here, the firstelectrode layer 430 corresponds to a pixel electrode. Further, aconductive layer 440 is formed over the thin film transistor 411 in thedriver circuit portion 404.

In the electrophoretic display device illustrated in FIG. 7, a secondelectrode layer 431 is formed over the second substrate 406.

The electrophoretic display element layer 413 sandwiched between thefirst electrode layer 430 and the second electrode layer 431 includes afiller material layer 408 and a twisting ball 489. The twisting ball 489includes a spherical particle 490 and a cavity 494 filled with liquidaround the spherical particle 490. The spherical particle 490 includes ablack region 490 a and a white region 490 b. The charge density of theblack region 490 a differs from that of the white region 490 b.Accordingly, a potential difference is generated between the firstelectrode layer 430 and the second electrode layer 431 so that thespherical particle 490 can be rotated depending on an electric fielddirection.

Note that in this embodiment, the driver circuit portion 404 is formedinside the frame of the sealant 405; however, the driver circuit portion404 is not necessarily formed in such a manner, and the entire or partof the driver circuit portion 404 may be formed outside the frame of thesealant 405. In the case of forming the driver circuit portion outsidethe frame of the sealant 405, the driver circuit portion may be formedover another substrate, and then mounted by a COG method, a wire bondingmethod, a TAB method or the like. For example, a scan line drivercircuit portion may be formed with a pixel portion inside the frame ofthe sealant over one substrate and a signal line driver circuit portionmay be formed over another substrate, and then mounted over the activematrix substrate.

Next, in accordance with the flow chart of FIG. 6, a method formanufacturing the electrophoretic display device illustrated in FIG. 7will be described.

In this embodiment, in accordance with the flow chart of FIG. 6,formation of a thin film transistor including an oxide semiconductorlayer (a step 141), formation of a sealant (a step 142), formation of anelectrophoretic display element layer (a step 143), attachment of afirst substrate and a second substrate (a step 144), curing of thesealant by ultraviolet light irradiation (a step 145), and heattreatment for repairing damage to the oxide semiconductor layer causedby the ultraviolet light irradiation (a step 146) will be described inthis order.

Formation of the thin film transistor including an oxide semiconductorlayer (the step 141) is the same or substantially the same as theformation of the thin film transistor including an oxide semiconductorlayer (the step 101) described in Embodiment 1; therefore, Embodiment 1is to be referred to. Materials and methods for manufacturing the firstsubstrate 401, the thin film transistor 410, the thin film transistor411, the insulating layer 420, the insulating layer 421, the firstelectrode layer 430, the conductive layer 440, the second substrate 406,and the second electrode layer 431 are the same or substantially thesame as the materials and methods for manufacturing the first substrate201, the thin film transistor 210, the thin film transistor 211, theinsulating layer 220, the insulating layer 221, the pixel electrodelayer 230, the conductive layer 240, the second substrate 206, and thecounter electrode layer 231 described in Embodiment 1, respectively;therefore, Embodiment 1 is to be referred to.

Next, formation of the sealant (the step 142) will be described.

The sealant 405 is formed by a screen printing method, or using anink-jet apparatus or a dispensing apparatus so as to surround the pixelportion 402 and the driver circuit portion 404 (closed-loop shape) overthe first substrate 401. The sealant may be formed to have a rectangularshape, a circular shape, an elliptical shape, a polygonal shape, or thelike, as appropriate. The sealant 405 does not necessarily surround thedriver circuit portion 404 as long as it surrounds at least the pixelportion 402. For example, the sealant 405 may be formed so as tosurround part of the driver circuit portion 404; alternatively, thedriver circuit portion 404 may be formed outside the frame of thesealant 405. The sealant 405 may be formed in the driver circuit portion404 and thus a frame of the electrophoretic display device can benarrowed.

The sealant 405 is not necessarily formed over the first substrate 401and may be formed over the second substrate 406. In the case where thesealant 405 is formed over the second substrate 406, the sealant 405 isformed so that the sealant 405 over the second substrate 406 surroundsat least the pixel portion 402 when the first substrate 401 and thesecond substrate 406 are attached to each other in a later step.

The sealant 405 is preferably formed using a material including anultraviolet curable resin. As the ultraviolet curable resin, a resin inwhich an acrylic-based resin and an epoxy-based resin are mixed can beused. Further, a UV initiator, a thermosetting agent, a coupling agent,or the like may be mixed into the resin. Furthermore, a filler (1 μm to24 μm in diameter) may be contained.

After the formation of the sealant 405, the sealant 405 may betemporarily cured by ultraviolet light irradiation. The ultravioletlight irradiation for temporarily curing the sealant 405 is performedwith a low intensity for a short time as compared with ultraviolet lightirradiation for curing (fully curing) the sealant in a later step.Although the oxide semiconductor layers of the thin film transistor 411and the thin film transistor 410 are damaged by the ultraviolet lightirradiation for temporarily curing the sealant 405, such damage can berepaired by heat treatment performed in a later step.

Next, formation of the electrophoretic display element layer (the step143) will be described.

The twisting ball 489 is disposed over the first electrode layer 430,and the filler is dropped in a region surrounded by the sealant 405formed over the first substrate 401 or the second substrate 406 by adroplet discharging method such as a dispensing method or an ink-jetmethod, so that the electrophoretic display element layer 413 is formed.At this time, an appropriate amount of liquid crystal may be dropped inappropriate places in the region surrounded by the sealant 405.

Alternatively, the twisting ball 489 may be contained in the fillermaterial layer 408 in advance, and the electrophoretic display elementlayer 413 may be formed by a droplet discharging method such as adispensing method or an ink-jet method.

As the filler, an ultraviolet curable resin or a thermosetting resin canbe used; for example, polyvinyl chloride (PVC), acrylic, polyimide, anepoxy resin, a silicone resin, polyvinyl butyral (PVB), or ethylenevinyl acetate (EVA) can be used. In the case of using an ultravioletcurable resin as the filler, the sealant 405 is not necessarily usedbecause the first substrate 401 and the second substrate 406 can be inclose contact with each other using the filler material layer 408.

In the case of using an ultraviolet curable resin as the filler, theoxide semiconductor layers of thin film transistors 410 and 411 aredamaged by ultraviolet light irradiation for curing; however, heattreatment performed later can repair damage to the oxide semiconductorlayer caused by ultraviolet light irradiation.

Next, attachment of the first substrate and the second substrate (thestep 144) will be described.

The sealant 405 is formed so as to surround the pixel portion 402 andthe driver circuit portion 404 (closed-loop shape), and then the firstsubstrate 401 and the second substrate 406 are attached to each other.Note that in the case where the sealant 405 and the filler materiallayer 408 are formed over the second substrate 406, it is necessary thatat least the pixel portion 402 of the first substrate 401 overlap withthe filler material layer 408.

Alternatively, after the first substrate 401 and the second substrate406 are attached to each other, the filler material layer 408 may beformed. In that case, an opening is formed in the sealant 405 when thesealant 405 is formed, and a space between the active matrix substrateand the second substrate 406 is filled with the filler by a vacuuminjection method or the like.

Next, curing of the sealant by ultraviolet light irradiation (the step145) will be described.

The first substrate 401 and the second substrate 406 are attached toeach other, and then curing (fully curing) of the sealant 405 isperformed by ultraviolet light irradiation. The ultraviolet lightirradiation for fully curing the sealant 405 is performed with a highintensity for a long time as compared with ultraviolet light irradiationfor temporarily curing the sealant in the above-described step.Accordingly, the ultraviolet curable resin inside the sealant 405 can becured, which can increase adhesiveness between the first substrate 401and the second substrate 406. The oxide semiconductor layers of the thinfilm transistors 410 and 411 are damaged when the sealant 405 isirradiated with ultraviolet light to be cured; however, heat treatmentperformed later can repair damage to the oxide semiconductor layercaused by ultraviolet light irradiation.

After the ultraviolet light irradiation of the sealant 405, heattreatment is preferably performed on the sealant 405. Accordingly, thesealant 405 can be cured more firmly. The heat treatment for curing thesealant 405 is preferably formed at a temperature of 80° C. to 200° C.for 0.5 hours to 10 hours. Heat treatment of the sealant afterultraviolet light irradiation is effective because a portion which isshaded and not irradiated with ultraviolet light in the ultravioletlight irradiation can be cured by the heat treatment.

In the case of using an ultraviolet curable resin as the filler, thefiller can be cured together with the sealant 405.

In the case where a plurality of panels is taken out from a pair ofsubstrates (obtaining a plurality of panels), the sealant 405 is curedand then, a pair of substrates which are attached is divided. The pairof substrates which are attached can be divided using a cuttingapparatus such as a scriber apparatus, a breaker apparatus, or a rollcutter.

Lastly, heat treatment for repairing damage to the oxide semiconductorlayer caused by the ultraviolet light irradiation (the step 146) will bedescribed.

In order to suppress shift of the threshold voltage of the thin filmtransistor in the negative direction, after all the steps of ultravioletlight irradiation are completed in the process for manufacturing theelectrophoretic display device, heat treatment for repairing damage tothe oxide semiconductor layer caused by ultraviolet light irradiation isperformed in a manner similar to that in Embodiments 1 to 3.

The heat treatment for repairing damage to the oxide semiconductor layeris performed preferably at a temperature of 50° C. to 300° C. for 0.5hours to 24 hours, further preferably at a temperature of 125° C. to250° C. for 1 hour to 15 hours. In addition, the heat treatment ispreferably performed under an air atmosphere, an oxygen atmosphere, anitrogen atmosphere, or a rare gas (such as helium, neon, or argon)atmosphere. The temperature of the heat treatment for repairing damageto the oxide semiconductor layer is preferably lower than that of theheat treatment for dehydration or dehydrogenation of the oxidesemiconductor layer. A heating method using an electric furnace or thelike can be employed for the heat treatment for repairing damage to theoxide semiconductor layer.

Realignment of atoms which exist in the oxide semiconductor layer or inthe vicinity thereof is gradually carried out by the heat treatment.According to this, it is possible to repair dangling bonds formed byultraviolet light irradiation in the oxide semiconductor layer, at theinterface between the oxide semiconductor layer and the gate insulatinglayer, or at the interface between the oxide semiconductor layer and theinsulating layer 420.

Damage to the oxide semiconductor layer by ultraviolet light can berepaired, so that a decrease in electric characteristics of the thinfilm transistor including the oxide semiconductor layer can be preventedand the shift of the threshold voltage in the negative direction can besuppressed.

In addition, even when the threshold voltage varies among thin filmtransistors formed over one substrate by ultraviolet light irradiation,the above-described heat treatment can reduce the variation in thethreshold voltage.

The channel length of the thin film transistor is shortened, so thathigh speed operation and low power consumption of the electrophoreticdisplay device can be achieved.

The heat treatment for repairing damage to the oxide semiconductor layercan also serve as heat treatment for curing the sealant 405 which isperformed after ultraviolet light irradiation of the sealant 405.

As described above, the electrophoretic display device is manufacturedby the method described in this embodiment, so that damage to an oxidesemiconductor layer caused by ultraviolet light irradiation can berepaired. According to this, even when the oxide semiconductor layer ofthe thin film transistor included in the electrophoretic display deviceis damaged by ultraviolet light in the process for manufacturing theelectrophoretic display device, shift of the threshold voltage of thethin film transistor in the negative direction due to the damage byultraviolet light irradiation can be suppressed.

Moreover, the thin film transistor that functions as a switching elementin the display device can be normally off, so that the electrophoreticdisplay device having low power consumption and high reliability can bemanufactured.

Embodiment 5

The electrophoretic display device described in Embodiment 4 can be usedfor electronic appliances of every field, which display information. Forexample, the electrophoretic display device (electronic paper) describedin Embodiment 4 can be used for electronic book (e-book), posters,advertisement in vehicles such as trains, display in a variety of cardssuch as credit cards. Examples of such electronic appliances areillustrated in FIGS. 8A to 8C.

FIG. 8A illustrates a poster 2631 formed using electronic paper. Whenthe advertizing medium is printed paper, the advertisement is replacedby manpower; however, when electronic paper is used, the advertisementdisplay can be changed in a short time. Moreover, a stable image can beobtained without display deterioration. Further, the poster may send andreceive information wirelessly.

When the electrophoretic display device described in Embodiment 4 isapplied to the poster 2631, the thin film transistor that functions as aswitching element can be normally off; thus, the poster 2631 having lowpower consumption and high reliability can be provided.

FIG. 8B illustrates an advertisement 2632 in a vehicle such as a train.When the advertizing medium is printed paper, the advertisement isreplaced by manpower; however, when electronic paper is used, theadvertisement display can be changed in a short time without muchmanpower. Moreover, a stable image can be obtained without displaydeterioration. Further, the advertisement in vehicles may send andreceive information wirelessly.

When the electrophoretic display device described in Embodiment 4 isapplied to the advertisement 2632 in a vehicle, the thin film transistorthat functions as a switching element can be normally off; thus, theadvertisement 2632 in a vehicle having low power consumption and highreliability can be provided.

FIG. 8C illustrates an example of an electronic book device. Forexample, an electronic book device 2700 includes two housings 2701 and2703. The housings 2701 and 2703 are combined with a hinge 2711, alongwhich the electronic book device 2700 is opened and closed. With such astructure, operation as a paper book is achieved.

A display portion 2705 is incorporated in the housing 2701 and a displayportion 2707 is incorporated in the housing 2703. The display portion2705 and the display portion 2707 may display one image or differentimages. In the structure where different images are displayed indifferent display portions, for example, the right display portion (thedisplay portion 2705 in FIG. 8C) can display text and the left displayportion (the display portion 2707 in FIG. 8C) can display images.

When the electrophoretic display device described in Embodiment 4 isapplied to the display portions 2705 and 2707, the thin film transistorthat functions as a switching element can be normally off; thus, theelectronic book device 2700 having low power consumption and highreliability can be provided.

FIG. 8C illustrates an example in which the housing 2701 is providedwith an operation portion and the like. For example, the housing 2701 isprovided with a power supply 2721, an operation key 2723, a speaker2725, and the like. The page can be turned with the operation key 2723.Note that a keyboard, a pointing device, and the like may be provided onthe same plane as the display portion of the housing. Further, a rearsurface or a side surface of the housing may be provided with anexternal connection terminal (an earphone terminal, a USB terminal, aterminal which can be connected with a variety of cables such as an ACadopter or a USB cable, and the like), a storage medium insertingportion, or the like. Moreover, the electronic book device 2700 may havea function of an electronic dictionary.

Further, the electronic book device 2700 may send and receiveinformation wirelessly. Desired book data can be purchased anddownloaded from an electronic book server wirelessly.

Embodiment 6

A display device disclosed in this specification can be applied to avariety of electronic appliances (including game machines). As theelectronic appliances, there are, for example, a television device (alsocalled TV or a television receiver), a monitor for a computer or thelike, a digital camera, a digital video camera, a digital photo frame, acellular phone (also called a mobile phone or a portable telephonedevice), a portable game machine, a portable information terminal, anaudio playback device, and a large game machine such as a pachinkomachine.

FIG. 9A illustrates an example of a television device. A display portion9603 is incorporated in a housing 9601 of a television device 9600. Thedisplay portion 9603 can display images. Here, the housing 9601 issupported on a stand 9605.

The television device 9600 can be operated by an operation switch of thehousing 9601 or a separate remote controller 9610. The channel andvolume can be controlled with operation keys 9609 of the remotecontroller 9610 and the images displayed in the display portion 9603 canbe controlled. Moreover, the remote controller 9610 may have a displayportion 9607 in which the information outgoing from the remotecontroller 9610 is displayed.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display portions 9603 and 9607, the thin filmtransistor that functions as a switching element can be normally off;thus, the television device 9600 having low power consumption and highreliability can be provided.

Note that the television device 9600 is provided with a receiver, amodem, and the like. With the use of the receiver, general televisionbroadcasting can be received. Moreover, when the display device isconnected to a communication network with or without wires via themodem, one-way (from a sender to a receiver) or two-way (between asender and a receiver or between receivers) information communicationcan be performed.

FIG. 9B illustrates an example of a digital photo frame. For example, adisplay portion 9703 is incorporated in a housing 9701 of a digitalphoto frame 9700. The display portion 9703 can display a variety ofimages, for example, displays image data taken with a digital camera orthe like, so that the digital photo frame can function as a normal photoframe.

Note that the digital photo frame 9700 is provided with an operationportion, an external connection terminal (such as a USB terminal or aterminal which can be connected to a variety of cables including a USBcable), a storage medium inserting portion, and the like. Thesestructures may be incorporated on the same plane as the display portion;however, they are preferably provided on the side surface or rearsurface of the display portion because the design is improved. Forexample, a memory including image data taken with a digital camera isinserted into the storage medium inserting portion of the digital photoframe and the image data is imported. Then, the imported image data canbe displayed in the display portion 9703.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display portion 9703, the thin film transistorthat functions as a switching element can be normally off; thus, thedigital photo frame 9700 having low power consumption and highreliability can be provided.

The digital photo frame 9700 may send and receive informationwirelessly. In this case, desired image data can be wirelessly importedinto the digital photo frame 9700 and can be displayed therein.

FIG. 9C illustrates a portable game machine including a housing 9881 anda housing 9891 which are jointed with a connector 9893 so as to be ableto open and close. A display portion 9882 and a display portion 9883 areincorporated in the housing 9881 and the housing 9891, respectively. Theportable game machine illustrated in FIG. 9C additionally includes aspeaker portion 9884, a storage medium inserting portion 9886, an LEDlamp 9890, an input means (operation keys 9885, a connection terminal9887, a sensor 9888 (including a function of measuring force,displacement, position, speed, acceleration, angular speed, the numberof rotations, distance, light, liquid, magnetism, temperature, chemicalsubstance, sound, time, hardness, electric field, current, voltage,electric power, radiation, flow rate, humidity, tilt angle, vibration,smell, or infrared ray), a microphone 9889, and the like). Needless tosay, the structure of the portable game machine is not limited to theabove and other structures provided with at least a display devicedisclosed in this specification may be employed. Moreover, anotheraccessory may be provided as appropriate. The portable game machineshown in FIG. 9C has a function of reading out a program or data storedin a storage medium to display it on the display portion, and a functionof sharing information with another portable game machine by wirelesscommunication. The portable game machine in FIG. 9C can have a varietyof functions other than those above.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display portions 9882 and 9883, the thin filmtransistor that functions as a switching element can be normally off;thus, the portable game machine having low power consumption and highreliability can be provided.

FIG. 9D illustrates a cellular phone including a housing 9440 and ahousing 9441. The housings 9440 and 9441 in a state where they aredeveloped as illustrated in FIG. 9D can overlap with each other bysliding. Thus, the size of the cellular phone can be reduced, whichmakes the cellular phone suitable for being carried. The housing 9441 isprovided with a display panel 9442, a speaker 9443, a microphone 9444, apointing device 9446, a camera lens 9447, an external connectionterminal 9448, and the like. Further, the housing 9440 is provided witha solar cell 9449 which charges the cellular phone, an external memoryslot 9450, and the like. In addition, an antenna is incorporated in thehousing 9441.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display panel 9442, the thin film transistorthat functions as a switching element can be normally off; thus, thecellular phone having low power consumption and high reliability can beprovided.

FIG. 9E is a perspective view of an example of a cellular phone that theuser can wear on the wrist like a wristwatch.

This cellular phone is formed with a main body which includes acommunication device including at least a telephone function, and abattery; a band portion which enables the main body to be worn on thewrist; an adjusting portion 9205 for adjusting the band portion to fitthe wrist; a display portion 9201; a speaker 9207; and a microphone9208.

In addition, the main body includes operation switches 9203. Theoperation switches 9203 can serve, for example, as a switch for startinga program for the Internet when pushed, in addition to serving as apower switch, a switch for switching displays, a switch for instructionto start taking images, or the like, and can be configured to haverespective functions.

A user can input data into this cellular phone by touching the displayportion 9201 with a finger or an input pen, operating the operationswitches 9203, or inputting voice into the microphone 9208. In FIG. 9E,display buttons 9202 are displayed on the display portion 9201. A usercan input data by touching the display buttons 9202 with a finger or thelike.

Further, the main body includes a camera portion 9206 including an imagepick-up means having a function of converting an image of an object,which is formed through a camera lens, to an electronic image signal.Note that the camera portion is not necessarily provided.

The cellular phone illustrated in FIG. 9E is provided with a receiver ofa TV broadcast and the like, and can display an image on the displayportion 9201 by receiving the TV broadcast. In addition, the cellularphone is provided with a memory device such as a memory, and the like,and can record the TV broadcast in the memory. The cellular phoneillustrated in FIG. 9E may have a function of collecting locationinformation such as GPS.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display portion 9201, the thin film transistorthat functions as a switching element can be normally off; thus, thecellular phone having low power consumption and high reliability can beprovided.

FIG. 9F is a perspective view illustrating an example of a portablecomputer.

In the portable computer illustrated in FIG. 9F, a top housing 9301having a display portion 9303 and a bottom housing 9302 having akeyboard 9304 can overlap with each other by closing a hinge unit whichconnects the top housing 9301 and the bottom housing 9302. Thus, theportable computer is conveniently carried. Moreover, in the case ofusing the keyboard for input of data, the hinge unit is opened so that auser can input data looking at the display portion 9303.

The bottom housing 9302 includes a pointing device 9306 with which inputcan be performed, in addition to the keyboard 9304. When the displayportion 9303 is a touch panel, a user can input data by touching part ofthe display portion. The bottom housing 9302 includes an arithmeticfunction portion such as a CPU or hard disk. In addition, the bottomhousing 9302 includes an external connection port 9305 into whichanother device, for example, a communication cable conformable tocommunication standards of a USB is inserted.

The top housing 9301 further includes a display portion 9307 which canbe stowed in the top housing 9301 by being slid therein. With thedisplay portion 9307, a large display screen can be realized. Inaddition, the user can adjust the angle of a screen of the displayportion 9307 that can be stored in the top housing 9301. If the displayportion 9307 that can be stored in the top housing 9301 is a touchpanel, the user can input data by touching part of the display portion9307.

The display portion 9303 or the display portion 9307 that can be storedin the top housing 9301 is formed using an image display device such asa liquid crystal display panel or a light-emitting display panel usingan organic light-emitting element, an inorganic light-emitting element,or the like.

When the electrophoretic display device described in any of Embodiments1 to 4 is applied to the display portion 9303, and the display portion9307 that can be stored in the top housing 9301, the thin filmtransistor that functions as a switching element can be normally off;thus, the portable computer having low power consumption and highreliability can be provided.

In addition, the portable computer illustrated in FIG. 9F can beprovided with a receiver and the like and can receive a TV broadcast todisplay an image on the display portion. The user can watch a TVbroadcast with the whole screen of the display portion 9307 by slidingand exposing the display portion 9307 and adjusting the angle thereof,with the hinge unit which connects the top housing 9301 and the bottomhousing 9302 closed. In this case, the hinge unit is not opened anddisplay is not performed on the display portion 9303. In addition, startup of only a circuit for displaying a TV broadcast is performed. Thus,power consumption can be minimized, which is useful for the portablecomputer whose battery capacity is limited.

Example 1

A so-called channel-etched thin film transistor was irradiated withultraviolet light, and then heat treatment for repairing damage to anoxide semiconductor layer was performed. In this example, evaluationresults of the threshold voltage of the transistor will be shown. Thethreshold voltage was measured at the following timings: after formationof the thin film transistor, and after the ultraviolet lightirradiation, and after the heat treatment for repairing damage to theoxide semiconductor layer.

In this example, eight thin film transistors with a channel length L of3 μm and a channel width W of 50 μm, eight thin film transistors with achannel length L of 4 μm and a channel width W of 50 μm, eight thin filmtransistors with a channel length L of 6 μm and a channel width W of 50μm, eight thin film transistors with a channel length L of 10 μm and achannel width W of 50 μm, and eight thin film transistors with a channellength L of 20 μm and a channel width W of 50 μm were formed over onesubstrate. The dependence of the threshold voltage on the channel lengthwas evaluated. First, a method for manufacturing the thin filmtransistors will be described.

First, as a base film, a stacked film of a 100-nm-thick silicon nitridefilm and a 150-nm-thick silicon oxynitride film was formed over a glasssubstrate by a CVD method. Over the silicon oxynitride film, a100-nm-thick tungsten film was formed as a gate electrode layer by asputtering method. Over the gate electrode layer, a 100-nm-thick siliconoxynitride film was formed as a gate insulating layer by a CVD method.

Next, a 30-nm-thick oxide semiconductor layer was formed using anIn—Ga—Zn—O-based oxide semiconductor target (In₂O₃:Ga₂O₃:ZnO=1:1:1[molar ratio]) under the following conditions: the distance between thesubstrate and the target was 60 mm, the pressure was 0.6 Pa, the directcurrent (DC) power supply was 0.5 kW, and an atmosphere of a chamber wasan oxygen atmosphere. The oxide semiconductor layer was etched so thatthe channel length L of the thin film transistor was any of 3 μm, 4 μm,6 μm, 10 μm, and 20 μm and the channel width W was 50 μm.

Then, heat treatment for dehydration or dehydrogenation was performed onthe oxide semiconductor layer under a nitride atmosphere at 650° C. for6 minutes, using a gas rapid thermal anneal (GRTA) apparatus.

As a source and drain electrode layers, a titanium film (100 nm inthickness), an aluminum film (200 nm in thickness), and a titanium film(100 nm in thickness) were stacked over the oxide semiconductor layer bya sputtering method.

Next, a silicon oxide film having a thickness of 300 nm was formed by asputtering method so as to be in contact with the oxide semiconductorlayer. An acrylic film having a thickness of 1.5 μm was formed over thesilicon oxide film as an interlayer film.

Then, the oxide semiconductor layer was subjected to heat treatmentunder a nitrogen atmosphere at 250° C. for 1 hour. After that, as awiring layer, a 110-nm-thick indium oxide-tin oxide alloy (ITSO) filmcontaining silicon at 5 wt. % was formed over the acrylic film by asputtering method.

Through the above steps, thin film transistors having a channel length Lof 3 μm, 4 μm, 6 μm, 10 μm, and 20 μm and a channel width W of 50 μmwere manufactured over one substrate.

Next, each of the transistors formed over one substrate is subjected toultraviolet light irradiation. In this case, the irradiation intensitywas 100 mW/cm² and the irradiation time was 3 minutes. The spectrum ofthe ultraviolet light is shown in FIG. 10. In FIG. 10, the vertical axisindicates the irradiation intensity (μW/cm²/nm) and the horizontal axisindicates the wavelength (nm). As seen from FIG. 10, the wavelength ofthe ultraviolet light is approximately 250 nm to 450 nm.

Next, as heat treatment for repairing damage to the oxide semiconductorlayer caused by ultraviolet light, heat treatment was continuouslyperformed under an air atmosphere for a long time, at a lowertemperature than the heat treatment for dehydration or dehydrogenation.Specifically, as the heat treatment for repairing damage to the oxidesemiconductor layer, heat treatment was performed at 150° C. for 15hours.

The threshold voltage of each of the thin film transistors was measuredafter formation of the thin film transistor, after the ultraviolet lightirradiation, and after the heat treatment for repairing damage to theoxide semiconductor layer, and current-voltage characteristics of eachof the thin film transistors was evaluated.

In FIG. 11, the threshold voltage of each of the thin film transistorsafter formation of the thin film transistor, after the ultraviolet lightirradiation, and after the heat treatment for repairing damage to theoxide semiconductor layer is shown. In FIG. 11, the vertical axisindicates the threshold voltage (Vth [V]) and the horizontal axisindicates the ratio of the channel length L to the channel width W (L[μm]/W [μm]).

The threshold voltage Vth is defined, in a graph where the horizontalaxis and the vertical axis indicate the gate voltage (Vg [V]) and thesquare root of drain current (Id^(1/2)) respectively, as a point ofintersection of the extrapolated tangent line of Id^(1/2) having thehighest inclination with the Vg axis.

As seen from FIG. 11, the threshold voltage is shifted in the negativedirection by the ultraviolet light irradiation from the thresholdvoltage after the formation of the thin film transistor. The thresholdvoltage is improved to substantially the same as the threshold voltageafter the formation of the thin film transistor by the heat treatmentfor repairing damage to the oxide semiconductor layer which is performedafter the ultraviolet light irradiation. Tendency of the thresholdvoltage was observed without depending on the channel length of the thinfilm transistor.

Further, although variation in threshold voltage of each thin filmtransistor becomes considerable in some degree by the ultraviolet lightirradiation, such variation is reduced by the heat treatment forrepairing damage to the oxide semiconductor layer.

As described above, the heat treatment for repairing damage byultraviolet light is performed after the ultraviolet light irradiation,damage to the oxide semiconductor layer can be repaired and the shift ofthe threshold voltage in the negative direction can be suppressed.According to this, even when the oxide semiconductor layer of the thinfilm transistor included in the display device is damaged by ultravioletlight in the process for manufacturing the display device, shift of thethreshold voltage of the thin film transistor in the negative directiondue to the damage by ultraviolet light irradiation can be suppressed.

This application is based on Japanese Patent Application serial no.2009-296066 filed with Japan Patent Office on Dec. 25, 2009, the entirecontents of which are hereby incorporated by reference.

1. A method for manufacturing a display device, comprising the steps of:forming a pixel portion comprising a thin film transistor comprising anoxide semiconductor layer comprising a channel formation region over afirst substrate; forming a sealant comprising an ultraviolet curableresin over the first substrate to surround at least the pixel portion;forming a liquid crystal layer comprising an ultraviolet curable resinto overlap the pixel portion by dropping a liquid crystal in a regionsurrounded by the sealant over the first substrate; attaching a secondsubstrate to the first substrate with the sealant between the secondsubstrate and the first substrate; irradiating the liquid crystal layerwith ultraviolet light; curing the sealant with ultraviolet lightirradiation after irradiating the liquid crystal layer with ultravioletlight; and performing heat treatment for repairing damage on the oxidesemiconductor layer caused by the ultraviolet light irradiation fromirradiating the liquid crystal layer with ultraviolet light and curingthe sealant.
 2. The method for manufacturing a display device accordingto claim 1, wherein the liquid crystal exhibits a blue phase.
 3. Themethod for manufacturing a display device according to claim 1, furthercomprising irradiating the sealant with ultraviolet light to betemporarily cured before forming the liquid crystal layer.
 4. The methodfor manufacturing a display device according to claim 1, wherein a pixelelectrode electrically connected to the thin film transistor issubjected to surface treatment by ultraviolet light irradiation.
 5. Themethod for manufacturing a display device according to claim 1, whereinthe first substrate is divided along with the second substrate aftercuring the sealant.
 6. The method for manufacturing a display deviceaccording to claim 1, wherein a second thin film transistor comprisingan oxide semiconductor layer is formed in a driver circuit portion ofthe display device, and wherein the sealant overlaps with the drivercircuit portion.
 7. The method for manufacturing a display deviceaccording to of claim 1, wherein the heat treatment is performed forgreater than or equal to 1 hour and less than or equal to 15 hours. 8.The method for manufacturing a display device according to claim 1,wherein the heat treatment is performed at greater than or equal to 125°C. and less than or equal to 250° C.
 9. A method for manufacturing adisplay device, comprising the steps of: forming a pixel portioncomprising a thin film transistor comprising an oxide semiconductorlayer comprising a channel formation region over a first substrate;forming a sealant comprising an ultraviolet curable resin over a secondsubstrate to surround at least the pixel portion; forming a liquidcrystal layer comprising an ultraviolet curable resin by dropping aliquid crystal in a region surrounded by the sealant over the secondsubstrate; attaching the first substrate to the second substrate withthe sealant between the first substrate and the second substrate so thatthe pixel portion overlaps with the liquid crystal layer; irradiatingthe liquid crystal layer with ultraviolet light; curing the sealant withultraviolet light irradiation after irradiating the liquid crystal layerwith ultraviolet light; and performing heat treatment for repairingdamage on the oxide semiconductor layer caused by the ultraviolet lightirradiation from irradiating the liquid crystal layer with ultravioletlight and curing the sealant.
 10. The method for manufacturing a displaydevice according to claim 9, wherein the liquid crystal exhibits a bluephase.
 11. The method for manufacturing a display device according toclaim 9, further comprising irradiating the sealant with ultravioletlight to be temporarily cured before forming the liquid crystal layer.12. The method for manufacturing a display device according to claim 9,wherein a pixel electrode electrically connected to the thin filmtransistor is subjected to surface treatment by ultraviolet lightirradiation.
 13. The method for manufacturing a display device accordingto claim 9, wherein the first substrate is divided along with the secondsubstrate after curing the sealant.
 14. The method for manufacturing adisplay device according to claim 9, wherein a second thin filmtransistor comprising an oxide semiconductor layer is formed in a drivercircuit portion of the display device, and wherein the sealant overlapswith the driver circuit portion.
 15. The method for manufacturing adisplay device according to of claim 9, wherein the heat treatment isperformed for greater than or equal to 1 hour and less than or equal to15 hours.
 16. The method for manufacturing a display device according toclaim 9, wherein the heat treatment is performed at greater than orequal to 125° C. and less than or equal to 250° C.
 17. A method formanufacturing a display device, comprising the steps of: forming a pixelportion comprising a thin film transistor comprising an oxidesemiconductor layer comprising a channel formation region over a firstsubstrate; forming a sealant comprising an ultraviolet curable resinover the first substrate to surround at least the pixel portion; forminga liquid crystal layer comprising an ultraviolet curable resin tooverlap the pixel portion by dropping a liquid crystal in a regionsurrounded by the sealant over the first substrate; attaching a secondsubstrate to the first substrate with the sealant between the secondsubstrate and the first substrate; irradiating the liquid crystal layerwith ultraviolet light; curing the sealant with ultraviolet lightirradiation after irradiating the liquid crystal layer with ultravioletlight; and performing heat treatment on the oxide semiconductor layer atgreater than or equal to 125° C. and less than or equal to 250° C. aftercuring the sealant with ultraviolet light irradiation.
 18. The methodfor manufacturing a display device according to claim 17, wherein theliquid crystal exhibits a blue phase.
 19. The method for manufacturing adisplay device according to claim 17, further comprising irradiating thesealant with ultraviolet light to be temporarily cured before formingthe liquid crystal layer.
 20. The method for manufacturing a displaydevice according to claim 17, wherein a pixel electrode electricallyconnected to the thin film transistor is subjected to surface treatmentby ultraviolet light irradiation.
 21. The method for manufacturing adisplay device according to claim 17, wherein the first substrate isdivided along with the second substrate after curing the sealant. 22.The method for manufacturing a display device according to claim 17,wherein a second thin film transistor comprising an oxide semiconductorlayer is formed in a driver circuit portion of the display device, andwherein the sealant overlaps with the driver circuit portion.
 23. Themethod for manufacturing a display device according to claim 17, whereinthe heat treatment is performed for greater than or equal to 1 hour andless than or equal to 15 hours.
 24. A method for manufacturing a displaydevice, comprising the steps of: forming a pixel portion comprising athin film transistor comprising an oxide semiconductor layer comprisinga channel formation region over a first substrate; forming a sealantcomprising an ultraviolet curable resin over a second substrate tosurround at least the pixel portion; forming a liquid crystal layercomprising an ultraviolet curable resin by dropping a liquid crystal ina region surrounded by the sealant over the second substrate; attachingthe first substrate to the second substrate with the sealant between thefirst substrate and the second substrate so that the pixel portionoverlaps with the liquid crystal layer; irradiating the liquid crystallayer with ultraviolet light; curing the sealant with ultraviolet lightirradiation after irradiating the liquid crystal layer with ultravioletlight; and performing heat treatment on the oxide semiconductor layer atgreater than or equal to 125° C. and less than or equal to 250° C. aftercuring the sealant with ultraviolet light irradiation.
 25. The methodfor manufacturing a display device according to claim 24, wherein theliquid crystal exhibits a blue phase.
 26. The method for manufacturing adisplay device according to claim 24, further comprising irradiating thesealant with ultraviolet light to be temporarily cured before formingthe liquid crystal layer.
 27. The method for manufacturing a displaydevice according to claim 24, wherein a pixel electrode electricallyconnected to the thin film transistor is subjected to surface treatmentby ultraviolet light irradiation.
 28. The method for manufacturing adisplay device according to claim 24, wherein the first substrate isdivided along with the second substrate after curing the sealant. 29.The method for manufacturing a display device according to claim 24,wherein a second thin film transistor comprising an oxide semiconductorlayer is formed in a driver circuit portion of the display device, andwherein the sealant overlaps with the driver circuit portion.
 30. Themethod for manufacturing a display device according to claim 24, whereinthe heat treatment is performed for greater than or equal to 1 hour andless than or equal to 15 hours.